CUTTER WITH A LOCKABLE RETENTION FEATURE

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Ser. No. 63/699,445 entitled “A Cutter with a Lockable Retention Feature” filed on Sep. 26, 2024, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND

Wellbores for the oil and gas industry are commonly drilled by a process of rotary drilling. In conventional rotary drilling, a drill bit is mounted to the end of a drill string, which may be extended to reach a desired depth by progressively adding tubing segments on site while drilling. In some drilling configurations, a rotary table or top drive included on a drilling rig turns the drill string, including the drill bit arranged within the wellbore, to progressively penetrate the subterranean formation while drilling fluid is pumped through the drill string. In other drilling configurations, the drill bit may be rotated using a downhole mud motor arranged adjacent the drill bit in the downhole environment and powered, for example, using the circulating drilling fluid.

A common type of drill bit used to drill wellbores is known as a “fixed-cutter” bit, which includes blades with cutters mounted thereon. As the drill bit rotates, and due to the alignment of the cutters positioned on the blades, the cutters make contact with the subterranean formation and deepen the wellbore by progressively shearing away layers of the subterranean rock.

Due to the hardness of the subterranean rock and the downhole drilling conditions to which the cutters are exposed, the cutters eventually dull and can even evacuate (dislodge from) the body of the drill bit entirely. The initial cutter installation is influential in extending the life of the cutter within the fixed-cutter blades.

Accordingly, an efficient means of cutter installation and cutter retention is desirable to improve the longevity of the cutter.

SUMMARY OF THE DISCLOSURE

Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

According to an embodiment consistent with the present disclosure, 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. The lock member includes 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.

According to an embodiment consistent with the present disclosure, a cutter for a drill bit includes 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. The lock member includes 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.

According to an embodiment consistent with the present disclosure, a drill bit includes 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. The cutter including a body; and a lock member having a plurality of locking features extending radially from the body. 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. 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.

Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following FIG. s are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

FIG. 1 is a schematic, isometric view of an example fixed-cutter drill bit that may incorporate the principles of the present disclosure.

FIG. 2A is a perspective view of an example cutter being inserted into an example pocket of a drill bit body.

FIG. 2B is a partial perspective view of the pocket formed within the drill bit body of FIG. 2A.

FIG. 2C is a cross-sectional side view of showing the cutter inserted into the pocket at a first rotational orientation.

FIG. 2D is a cross-sectional side view showing the cutter at a second rotational orientation within the pocket.

FIG. 3 is a perspective view of a two-piece cutter having a first portion and a second portion.

FIG. 4A is a cross-sectional view of the second portion of the cutter of FIG. 3 disposed within a pocket at a first rotational orientation.

FIG. 4B is a cross-sectional view of the second portion of the cutter of FIG. 3 disposed within the pocket at a second rotational orientation.

FIG. 4C is a cross-sectional view showing the first portion of the cutter of FIG. 3 connected to the second portion of the cutter after rotating the second portion to the second rotation orientation.

DETAILED DESCRIPTION

Embodiments in accordance with the present disclosure generally relate to mounting cutters to fixed-cutter drill bits and, more particularly, to polycrystalline diamond compact (PDC) cutters that include retention features that help retain the cutters within corresponding pockets of the drill bit.

PDC cutters for fixed-cutter drill bits (both tungsten and matrix) are conventionally brazed in place within corresponding bit pockets formed in the drill bit. While drilling a wellbore, varying drilling conditions (e.g., flow rates, axial forces, heavy vibrations, erosion, etc.) can lead to PDC cutters evacuating (dislodging from) a manufactured bit pocket. Moreover, since brazing is largely a human process, there is potential for cutters to be lost due to impurities present during the brazing process and/or improper brazing procedures. When PDC cutters are lost during drilling operations, drill bits can be prematurely damaged, which can result in lost time due to bit trips or inefficient drilling, while also potentially causing costly damage to the drill bit and inhibiting the ability to repair the drill bit.

Embodiments of the present disclosure describe methods of mechanically retaining PDC cutters in a corresponding bit pocket, and thereby increasing drill bit durability and performance. The PDC cutters are locked into the bit pocket with a mechanical retention feature. More particularly, the PDC cutters are inserted into the bit cutter at a first rotational orientation such that the retention feature is aligned with an insertion profile of the bit pocket and then angularly rotated to a second rotational orientation to misalign the retention feature with the insertion profile and to engage the retention feature with a locking profile of the bit pocket, thereby locking the PDC cutter within the bit pocket and aligning the PDC cutter in a desired rotational orientation with respect to the bit cutter.

The retention features described herein help mitigate risk of lost cutters during drilling operations, and may also aid in ensuring the proper placement and centralization of the cutter within the fixed-cutter drill bit during installation. Also, the retention features improve the standoff of the face of the cutting surface, which increases the rate of penetration. The retention features described herein may also ensure a successful brazing operation, where brazing is used to join cutters to the fixed-cutter drill bit during initial installation. Embodiments described herein limit risk exposure to damaged drill bits beyond repair.

FIG. 1 is a schematic, isometric view of an example fixed-cutter drill bit 100 that may employ the principles of the present disclosure. The fixed-cutter drill bit 100 (hereafter the “drill bit 100”) has a bit body 102 that includes radially and longitudinally extending blades 104 having leading faces 106, and a threaded pin connection 108 for connecting the bit body 102 to a drill string (not shown). The bit body 102 may be made of steel or a metal matrix of a harder material, such as tungsten carbide. The bit body 102 is configured for rotation about a longitudinal axis 110 to drill into a subterranean formation via application of weight on the bit body 102. Those of ordinary skill in the art will be familiar with other prominent features of the drill bit 100 including, but not limited to, the shoulder, the nozzles (alternatively referred to as ports), the cone, the nose, etc. However, those features are beyond the scope of this disclosure and will not be discussed in any detail.

A plurality of cutters 112 are secured to the bit body 102 and, more particularly, to the blades 104. Each cutter 112 may be positioned within a corresponding cutter pocket 114 that is sized and shaped to receive the respective cutter 112. The cutters 112 are held in the blades 104 and corresponding cutter pockets 114 at predetermined angular orientations and radial locations to position the cutters 112 at a desired backrake angle against the formation being penetrated. As the bit body 102 is rotated, the cutters 112 are driven against and through the underlying rock formation by the combined forces of weight-on-bit and torque assumed at the drill bit 100.

During manufacture of the drill bit 100, the cutters 112 are secured within the pockets 114 by brazing, which is a well-known method of joining materials of differing metallurgy via heat. Because the brazing process is traditionally performed by a human, there is potential for human error and impurities presented in the braze material (e.g., metal solder), which may result in the loss of cutters 112 when the drill bit 100 is placed in use and otherwise exposed to downhole drilling conditions. To ensure a consistent braze, operators will often utilize some method or means of holding the cutter 112 in place during the brazing process. However, despite such an attempt to retain the cutter 112 in place, the cutters 112 may tend to “float” within the pockets 114 while the braze is being applied. In such instances, upon cooling, the cutter 112 may not be secured or seated as originally designed within the pocket 114. Such an anomaly may leave the cutter 112 susceptible to both damage and loss.

Downhole drilling conditions, including flow rates, axial forces, heavy vibration, and erosion, will inevitably lessen the life of the cutters 112. In some cases, drilling conditions and parameters may cause the cutters 112 to be dislodged from their respective pockets 114 during drilling operation. A gap between the bottom surface of the cutter 112 and the pocket 114 may result from poor brazing practices, which can further increase the risk of cutter 112 evacuation and potential downhole loss. A loss of a plurality of the cutters 112 may require the drill bit 100 to be returned to surface for repair or replacement earlier than planned, resulting in added time and cost.

According to embodiments of the present disclosure, the cutters 112 secured to the drill bit 100 may include a retention feature that serves to securely hold the cutter 112 in place within both steel and matrix drill bits. The retention features described herein aid in at least two ways. First, the retention features assist in ensuring proper placement and centering of the cutter 112 within the corresponding pocket 114 during brazing operations. The cutters 112 are not prone to “floating” because the retention features eliminate the need for an external retention device during brazing. Retained cutters 112 offer improved quality assurance of the position of the cutter 112 within the drill bit 100, or more particularly, the pocket 114. Second, the retention features help increase the likelihood that the cutter 112 will remain in place even when exposed to extreme downhole drilling conditions. The retention features mitigate risk of premature bit failures due to loss of one or more of the cutters 112.

FIG. 2A illustrates an enlarged portion of the drill bit 100 of FIG. 1 showing installation of an example cutter 112, according to the principles of the present disclosure. The cutter 112 is shown prior to being inserted into a corresponding pocket 114 formed within the bit body 102. Only a cylindrical portion of the bit body 102 is shown in FIG. 2A, and the portion of the bit body 102 depicted in FIG. 2A may form part of a blade formed on the bit body 102.

As illustrated, the cutter 112 includes a substrate 202, a cutting layer 204, and a lock member 206. The substrate 202 may be made of an extremely hard material, such as tungsten carbide (WC) or a ceramic. In some embodiments, the substrate 202 may comprise a cylindrical WC “blank” that is sufficiently long to act as a mounting stud for the cutting layer 204. In other embodiments, the substrate 202 may comprise an intermediate layer bonded at another interface to another metallic mounting stud, without departing from the scope of this disclosure.

The cutting layer 204 may be a diamond table (e.g., disk). The cutting layer 204 incorporates one or more layers of ultra-hard material, including but not limited to polycrystalline diamond (PCD), polycrystalline cubic boron nitride, sintered tungsten carbide, thermally stable polycrystalline (TSP), natural or synthetic diamond, hardened steel, or any combination thereof. Accordingly, the resulting cutter 112 may be characterized and otherwise referred to herein as a “polycrystalline diamond compact” cutter 112 or a PDC cutter 112. The particular composition of the cutting layer 204, however, is not limiting to the scope of this disclosure. In some embodiments, the cutting layer 204 may have the same outer diameter as the substrate 202.

In some embodiments, and as shown in FIG. 2A, the lock member 206 may be integral to the substrate 202. The lock member 206 includes a retention feature 208 that is used to align and lock the cutter 112 within the pocket 114. As illustrated, the retention feature 208 includes a body 210, which may comprise a cylindrical portion of the lock member 206 and may exhibit an outer diameter that is smaller than the outer diameter of the substrate 202. The retention feature 208 also includes at least one locking feature 211 that protrudes radially outward from the body 210. More specifically, the retention feature 208 may provide or otherwise define one or more lobed locking features 211. In some embodiments, the cutter 112 may have two or more locking features 211, such as four locking features equidistantly (or non-equidistantly) spaced from each other. In some embodiments, the locking features 211 are formed by machining the body 210. The locking features 211 may not protrude past the outer diameter of the substrate 202. However, the locking features 211 may protrude to the outer diameter of the substrate 202 such that the radial ends or extents of the locking features 211 align flush with the outer circumference of the substrate 202.

FIG. 2A shows the cutter 112 in a first rotational orientation prior to being inserted into the bit pocket 114. As illustrated, the pocket 114 has (provides) a first pocket portion 212, and a second pocket portion 214 that extends from the first pocket portion 212 and deeper into the bit body 102. The first pocket portion 212 is shown as a cylindrical bore that leads to the second pocket portion 214. A shoulder 216 is formed at the bottom of the first pocket portion 212 and is engageable with a corresponding shoulder 218 of the lock member 206 when the cutter 112 is advanced into the bit pocket 114.

FIG. 2B is an enlarged, partial perspective view of the pocket 114 formed in the bit body 102 to better illustrate the second pocket portion 214. The second pocket portion 214 provides a profile 220 configured to receive the retention feature 208 (FIG. 2A) of the cutter 112 (FIG. 2A). As illustrated, the profile 220 may provide or define two levels or sections. The first level, which is closest to the first pocket portion 212, is an insertion profile 222 that facilitates insertion of the retention feature 208 (FIG. 2A) into the second pocket portion 214 while the cutter 112 is in the first rotational orientation. The second level of the profile 220 is a locking profile 224 that helps retain the cutter 112 (FIG. 2A) within the pocket 114 once the retention feature 208 advanced into the locking profile 224 and the cutter 112 is rotated to a second rotational orientation. The shoulder 216 is provided at the end of the first pocket portion 212 and is partially defined by the insertion profile 222.

The insertion profile 222 may include or define a plurality of insertion recesses 226 sized to align with and receive a corresponding locking feature 211 (FIG. 2A) of the cutter 112 (FIG. 2A). The insertion recesses 226 each exhibit a shape or geometry that is complementary to the shape or geometry of the corresponding locking feature 211. The insertion recesses 226 are depicted in FIG. 2B as lobed recesses, and are thus configured to receive a corresponding lobed locking feature 211. Moreover, each insertion recess 226 may be angularly separated from one another by a surface 228, which is shown as an arcuate surface shown in FIG. 2B. The surface 228 may be complementary to the surface of the body 210 (FIG. 2A). The cutter 112 is inserted into the insertion profile 222 while in the first rotational orientation such that each locking feature 211 is angularly aligned with a corresponding insertion recess 226.

The locking profile 224 may further include or otherwise define a plurality of locking recesses 230. The locking recesses 230 are shaped such that a corresponding locking feature 211 (FIG. 2A) of the cutter 112 (FIG. 2A) can advance through a corresponding insertion recess 226 and be received into a corresponding locking recess 230 when the cutter 112 is in the first rotational orientation. The locking recess 230 is also shaped such that the cutter 112 can be rotated to the second rotational orientation to misalign the locking feature 211 with the insertion recess 226, thereby axially locking the locking feature 211 within the pocket 114. For example, and as shown in FIG. 2B, portions of the locking recesses 230 extend under (beneath) the surface 228 that separates the insertion recesses 226. Each locking recess 230 includes a locking surface 232, which may comprise a shelf formed by the overhang of the insertion profile 222 relative to the locking profile 224. When the cutter 112 is rotated to the second rotational orientation, an upper surface of the locking feature 211 is engageable with the underside of the locking surface 232, which prevents axial removal of the retention feature 208 from the pocket 114. Rotating the cutter 112 back to the first rotational orientation aligns the locking feature 211 once again with the insertion recess 226, which allows the cutter 112 to be removed axially from the pocket 114.

The locking profile 224 is also shaped and otherwise designed to properly align and center the cutter 112 (FIG. 2A) within the pocket 114 during brazing. Thus, in addition to axially securing the cutter 112 within the pocket 114, the locking profile 224 also aligns and centers the cutter 112 within the pocket 114. In some embodiments, each locking recess 230 includes a stop surface 225 that provides a hard rotational stop that limits rotation of the cutter 112 when rotating the cutter 112 to the second rotational orientation. In other words, the cutter 112 reaches the second rotational orientation once the cutter 112 is rotated to abut each locking feature 211 against the stop surface 225 of the respective locking recess 230. For example, the locking profile 224 may be shaped such that the cutter 112 can rotate a set number of degrees, such as 45 degrees, in either the clockwise or counter-clockwise direction, to contact the stop surfaces 225 and thereby place the cutter 112 in the second rotational orientation. Upon reaching the second rotational orientation, the cutter 112 will be properly aligned within the pocket 114 to facilitate brazing.

FIG. 2C is a cross-sectional, enlarged view of the cutter received within the cutter pocket 114, according to one or more embodiments. As shown, the cutter 112 is inserted into the pocket 114 of the bit body 102 at the first rotational orientation such that the retention feature 208 is disposed within the second pocket portion 214. In at least one embodiment, the cutter 112 can be advanced into the pocket 114 in the first rotational orientation until the bottom of the cutter 112 contacts the bottom of the pocket 114 within the second pocket portion 214. As shown, in the first rotational orientation, the locking features 211 protruding from the body 210 are angularly aligned with the insertion recesses 226 of the insertion portion 222 and thus can be advanced into the locking profile 224. Once the locking features 211 are properly received within the locking profile 224, the cutter 112 can then be rotated about a longitudinal axis 234 thereof to the second rotational orientation shown in FIG. 2D. In some embodiments, for example, the cutter 112 may be rotated 45 degrees in a clockwise (or counter-clockwise) direction to place the cutter 112 in the second rotational orientation.

FIG. 2D shows the cutter 112 in the second rotational orientation with the locking features 211 misaligned with the corresponding insertion recess 226 (FIGS. 2B and 2D), and thus axially secured within the bit body 102. Each locking feature 211 is disposed in the locking profile 224 and is prevented from being withdrawn axially from the pocket 114 by the opposing locking surface 232. The cutter 112 may then be brazed to the bit body 102. Locking the cutter 112 within the pocket 114 advantageously removes the need for the brazer (i.e., person who undertakes the brazing process) to use equipment (or hands) to hold the cutter 112 in place during brazing, which helps facilitate a better quality braze, also ensuring proper alignment of the cutter 112 while preventing the cutter from ‘floating’ during the brazing process.

The braze 250 is schematically shown in FIG. 2D. In some embodiments, only a portion of the outer surface of the cutter 112 is brazed, such as a portion of the cutter 112 within the first pocket portion 212 identified by reference sign 251 (first portion of the braze 250). In some embodiments, the braze may extend to the second pocket portion 214 such that the retention feature 208 also becomes brazed to the bit body 102, as identified by reference sign 252 (second portion of the braze 250).

The cutter 112 can be removed from the pocket 114 after unlocking the cutter 112 by flowing the braze 250 and returning the cutter 112 to the first rotational orientation. For example, the cutter 112 may be removed after being used to drill a portion of the wellbore. A new cutter 112 may then be inserted into the pocket 114.

FIG. 3 is an isometric, exploded view of another example cutter 300 that may incorporate the principles of the present disclosure. The cutter 300 may be similar in some respects to the cutter 112 of FIGS. 1 and 2A-2D, and therefore may be best understood with reference thereto, where like numerals will represent like components not described again in detail. Similar to the cutter 112, for example, the cutter 300 may be configured to be attached to the bit body 102 (FIG. 1), and the cutter 300 is designed to be inserted into and axially locked within the pocket 114.

Unlike the cutter 112 (FIGS. 1 and 2A-2D), however, the cutter 300 comprises a two-part cutter. More specifically, as illustrated, the cutter 300 includes a first cutter portion 302 and a second cutter portion 304. The first cutter portion 302 may include a substrate 306 and a cutting layer 308. The substrate 306 and the cutting layer 308 may be made of similar materials as the substrate 202 (FIG. 2A) and the cutting layer 204 (FIG. 2A), respectively, of the cutter 112 (FIG. 2A). As shown, the first cutter portion 302 includes a plug 310, which may be integrally formed with the substrate 306 but exhibits an outer diameter that is less than the major outer diameter (e.g., largest outer diameter) of the rest of the first cutter portion 302. In some embodiments, the end of the plug 310 may have a beveled edge 312. The first portion 302 may have a torque profile 324 formed on the face 326 of the cutting layer 308.

The second cutter portion 304 may comprise and otherwise operate as a lock member, and is hereinafter referred to as the “lock member 304.” The lock member 304 includes the retention feature 208, as generally described above, and a socket 314. The socket 314 exhibits a complementary profile or geometry to the profile or geometry of the plug 310. For example, the socket 314 and the plug 310 may each have circular cylindrical profile or geometry to allow the first cutter portion 302 to freely rotate relative to the lock member 304 with the plug 310 received within the socket 314 and during a brazing process.

The lock member 304 may have a shoulder 316 at a first end opposite the retention feature 208. The shoulder 316 is a portion of the face of the first end that is present around the entrance of the socket 314. The shoulder 316 is engageable with a corresponding shoulder 318 of the substrate 306 that extends about the periphery of the plug 310. In some embodiments, the socket 314 may include or define a beveled edge 320 at an end of the socket 314 that is engageable with the beveled edge 312 of the plug 310. The opposing beveled edges 312, 320 may help the plug 310 to be received within the socket 314.

The socket 314 is formed in a socket portion 322 of the lock member 304. The retention feature 208 is disposed on one side of the socket portion 322 while the opening to the socket 314 is located at the other (opposite) side of the socket portion 322. As shown, the body 210 of the retention feature 208 has an outer diameter that is less than the outer diameter of the socket portion 322. In some embodiments, the socket portion 322 has an outer diameter that is the same as or less than the outer diameter of the major outer diameter of the first cutter portion 302.

FIGS. 4A-4C are cross-sectional side views showing progressive and example installation of the cutter 300 of FIG. 3 into the pocket 114 of the bit body 102. The lock member 304 is first inserted (advanced) into the pocket 114, as shown in FIG. 4A, and then locked within the pocket 114, as shown in FIG. 4B, following which the first cutter portion 302 may be inserted into and received by the lock member 304, as shown in FIG. 4C.

Referring first to FIG. 4A, the lock member 304 is shown after being inserted into the pocket 114 at the first rotational orientation such that the lock member 304 is received into the second pocket portion 214. As shown, the lock member 304 is advanced into the pocket 114 at the first rotational orientation such that the locking features 211 are in alignment with the insertion recesses 226 of the insertion profile 234 and disposed within the locking profile 224. The lock member 304 is then rotated about the longitudinal axis 234 to the second rotational orientation (e.g., see FIG. 4B) to axially lock the lock member 304 within the pocket 114. In at least one embodiment, the lock member 304 may be angularly rotated until further rotation is prevented by the locking profile 224. For example, the lock member 304 may be rotated 45 degrees in a clockwise (or counter-clockwise) direction to place the lock member 304 in the second rotational orientation.

FIG. 4B shows the lock member 304 in the second rotational orientation, with the locking features 211 misaligned with the corresponding insertion recess 226 (FIG. 4A). In this angular orientation, each locking feature 211 is prevented from being axially withdrawn from the pocket 114 by the opposing locking surface 232.

Referring now to FIG. 4C, once the lock member 304 is transitioned (rotated) to the second rotational orientation, the first cutter portion 302 of the cutter 300 (FIG. 3) may then be inserted into the pocket 114. To accomplish this, the plug 310 is advanced into the pocket 114 and inserted into the socket 314. The socket 314 and the plug 310 cooperatively align the first cutter portion 302 within the pocket 114. As the plug 310 is advanced into the socket 314, the shoulders 316, 318 eventually come into contact with each other. The first cutter portion 302 is freely rotatable relative to the lock member 304, and a brazer (i.e., someone undertaking a brazing process) is free to rotate the first cutter portion 302 relative to the lock member 304 about the axis 234 during a brazing process to form a high quality and even braze between the first cutter portion 302 and the body 102. In some applications, the brazer may rotate the first cutter portion 302 by engaging a rotational tool with the torque profile 324 formed on the face 326 of the cutting layer 308.

The braze 400 is schematically shown in FIG. 4C. In some embodiments, only a portion of the surface of the cutter 300 is brazed, such as a section of the first cutter portion 302 within the first pocket portion 212 identified by reference sign 401 (first portion of the braze 400). In other embodiments, the braze 400 may extend to the second pocket portion 214 to braze the lock member 304 to the body 102 as identified by the second portion 402 of the braze 400. In yet other embodiments, the braze 400 may flow into the interface between the plug 310 and the socket 314 such that the first cutter portion 302 becomes brazed to the lock member 304 as identified by the third portion 403 of the braze 400.

In some embodiments, the cutter 300 can be removed from the pocket 114 by flowing the braze and then removing the first cutter portion 302, and then returning the lock member 304 to the first rotational orientation. A new cutter 300 may then be inserted into the pocket 114.

In some embodiments, the cutter 300 can be removed from the pocket 114 by rotating the first cutter portion 302, such as engaging the torque profile 324 with a rotary tool, which causes the first cutter portion 302 and second cutter portion 304 to rotate to align the locking features 211 with the insertion profile 222. In other words, the first cutter portion 302 may be sufficiently brazed to the lock member 304 such that torque applied to the first cutter portion 302 is transferred to the lock member 304. The cutter 300 can then be removed. A new cutter 300 may then be inserted into the pocket 114.

Embodiments disclosed herein include:

• • A. 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. The lock member includes 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.
  • B. 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. The lock member includes 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.
  • C. 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. The cutter including a body; and a lock member having a plurality of locking features extending radially from the body. 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. 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.

Element 1: wherein the lock member is integral with the substrate. Element 2: 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. Element 3: wherein the plug is freely rotatable within the socket prior to brazing the substrate to the drill bit body. Element 4: wherein the plug has a first cylindrical profile and the socket has a second cylindrical profile matable with the first cylindrical profile. Element 5: 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. Element 6: wherein the cutting layer provides a torque profile defined on a face of the cutting layer. Element 7: wherein the at least one locking feature comprises four locking features angular spaced from each other about the body. Element 8: wherein the plug has a first cylindrical profile and the socket has a second cylindrical profile matable with the first cylindrical profile. Element 9: wherein an outer diameter of the socket portion is the same as the first outer diameter. Element 10: wherein an end of the plug has a beveled edge around an end face of the plug. Element 11: 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. Element 12: wherein the cutting layer provides a torque profile defined on a face of the cutting layer. Element 13: wherein the plug is brazed to the socket. Element 14: wherein the lock member is integral with a substrate of the cutter. Element 15: wherein the lock member includes a socket configured to receive a plug extending from the substrate. Element 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. Element 17: wherein the cutter includes a cutting layer and a substrate, and wherein the body is formed integrally with the substrate.

By way of non-limiting example, exemplary combinations applicable to A, B, and C include: Element 2 with element 3, Element 2 with Element 4, and Element 2 with Element 5.

Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

The use of directional terms such as above, below, upper, lower, upward, downward, left, right, uphole, downhole and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure, the uphole direction being toward the surface of the well and the downhole direction being toward the toe of the well.