BEARING ASSEMBLY
20220373020 · 2022-11-24
Inventors
- Biju VARGHESE (Westerville, OH, US)
- Venkata Durga Prasad KAPPAGANTULA (Lewis Center, OH, US)
- Anshul SINGH (Columbus, OH, US)
- Andrew GLEDHILL (Westerville, OH, US)
- Joseph M. Rhodes (Pataskala, OH, US)
Cpc classification
F16C2352/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B1/00
PERFORMING OPERATIONS; TRANSPORTING
F16C2206/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C17/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2206/56
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C43/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
F16C2206/82
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B3/30
PERFORMING OPERATIONS; TRANSPORTING
B32B9/005
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
Provided are bearing assemblies including one or more substrate assemblies, such as thrust bearing assemblies. The substrate assemblies include a bearing element fixed to a substrate. The bearing elements are formed from a thermally stable material such as a ceramic-bonded diamond composite. Methods for manufacturing the bearing assemblies are also provided.
Claims
1. A bearing assembly, comprising: at least one substrate assembly, the substrate assembly comprising at least one substrate having a surface; at least one bearing element comprising a ceramic-bonded diamond composite material: and a composition comprising an epoxy affixing the at least one bearing element to the substrate at a recess in the substrate surface, wherein the one or more bearing elements are within 0.001″ coplanarity as measured from the substrate surface.
2. The bearing assembly according to claim 1, wherein the substrate comprises a substantially annular ring shape.
3. The bearing assembly according to claim 1, wherein the substrate is formed from a material comprising steel.
4. The bearing assembly according to claim 1, wherein the substrate is formed from a material comprising a cemented carbide.
5. The bearing assembly according to claim 1, wherein the ceramic-bonded diamond material comprises, by weight, about 90% diamond grains, 9% silicon carbide bonded to the diamond grains and 1% unreacted silicon metal.
6. The bearing assembly according to claim 1, wherein the ceramic-bonded diamond material comprises, by weight, about 50-99% diamond grains, 1-25% silicon carbide bonded to the diamond grains and 0.01-5% unreacted silicon metal.
7. The bearing assembly according to claim 6, wherein the adhesive formulation comprises silicic acid. steel fines an epoxy resin.
8. The bearing assembly according to claim 1, wherein the bearing element comprises a bearing face formed in a shape selected from the group consisting of a circle. a square, a rectangle, a triangle, a trapezoid, a nonagon, a octagon, a heptagon, a hexagon, a scalene triangle, a right triangle. a parallelogram. a rhombus, a square. a pentagon, a circle, an oval, a star and a crescent, or the like.
9. The bearing assembly according to claim 1, wherein the bearing element comprises a fluid restriction element.
10. The bearing assembly according to claim 1, wherein the substrate comprises a fluid restriction element.
11. The bearing assembly according to claim 1, wherein the substrate comprises a first substrate body and a second substrate body joined together.
12. The bearing assembly according to claim 11. wherein the first substrate body and the second substrate are different materials.
13. The bearing assembly according to claim 11. wherein the first substrate body is formed from a tungsten carbide and the second substrate body is formed from steel.
14. A method of manufacturing a bearing assembly comprising at least one substrate assembly, the method comprising: providing a substrate having one or more recesses; applying a composition comprising an epoxy into each of the recesses; inserting a thermally stable bearing element comprising a ceramic-bonded diamond composite material into each of the recesses to obtain a wet substrate assembly; placing a bottom alignment plate into a pneumatic press; stacking the wet substrate assembly onto the bottom alignment plate; optionally, placing a separator material on top of the wet substrate assembly; placing a top alignment plate on top of the wet assembly, with or without the separator material therebetween; pressing the wet substrate material with pneumatic press at a pressure of from 30 to 120 psi for a period of from 5 to 15 seconds; removing the pressed wet substrate assembly; and curing the wet substrate assembly for about 24 hours to obtain the at least one substrate assembly.
15. The method according to claim 14, wherein the substrate comprises a substantially annular ring shape.
16. The method according to claim 14, wherein the substrate is formed from a material comprising steel.
17. The method according to claim 14, wherein the substrate is formed from a material comprising a cemented carbide.
18. The method according to claim 14, wherein the ceramic-bonded diamond material comprises, by weight, about 90% diamond grains, 9% silicon carbide bonded to the diamond grains and 1% unreacted silicon metal.
19. The method according to claim 14, wherein the ceramic-bonded diamond material comprises, by weight, about 50-99% diamond grains, 1-25% silicon carbide bonded to the diamond grains and 0.01-5% unreacted silicon metal.
20. The method according to claim 14, wherein the adhesive formulation comprises silicic acid, steel fines and an epoxy resin.
21. The method according to claim 14, wherein the bearing element comprises a bearing face formed in a shape selected from the group consisting of a circle, a square, a rectangle, a triangle, a trapezoid, a nonagon, a octagon, a heptagon, a hexagon, a scalene triangle, a right triangle, a parallelogram, a rhombus, a square, a pentagon, a circle, an oval, a star and a crescent, or the like.
22. The method according to claim 14, wherein the bearing element comprises a fluid restriction element.
23. The method according to claim 14, wherein the substrate comprises a fluid restriction element.
24. The method according to claim 14, wherein the substrate comprises a first substrate body and a second substrate body joined together.
25. The method according to claim 24, wherein the first substrate body and the second substrate are different materials.
26. The method according to claim 24, wherein the first substrate body is formed from a tungsten carbide and the second substrate body is formed from steel.
Description
BRIEF DESCRIPTION OF THE DRAWING
[0026] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate implementations of the invention and together with the description serve to explain the principles of the disclosure.
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[0042] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals should be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience. Also, for ease of viewing, in some instances only some of the named features in the figures are labeled with reference numerals.
DETAILED DESCRIPTION
[0043] Unless defined otherwise all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently described subject matter pertains.
[0044] Where a range of values is provided, for example, concentration ranges, percentage ranges, or ratio ranges, it is understood that each intervening value, to the tenth of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the described subject matter. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and such embodiments are also encompassed within the described subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the described subject matter.
[0045] Turning to the drawing figures,
[0046] As shown in
[0047] The bearing assembly may include a fluid restriction element (not shown) to increase the turbulence of, e.g., drilling fluid flow between the bearing elements 105. The fluid restriction element is designed to increase the Reynold's number of the fluid flowing between the bearing elements 105, thereby increasing the eddy currents and cavitation within the fluid, and as a result, increasing convective heat transfer.
[0048] For example, with specific regard to thrust bearing assemblies and radial bearing assemblies used in down hole drilling, drilling fluid acts as both a lubricant to the substrate assembly contact area (i.e., the face 111 of the bearing elements 105), and as a source of heat transfer, pulling heat away from the bearing elements 105. Increased turbulence in this flow will greatly improve the heat transfer from the bearing elements 105 to the drilling fluid (not shown).
[0049] In the field of fluid dynamics, the Nusselt number is the ratio of convective heat transfer to conductive heat transfer at the boundary of a system. In the present example, at the boundary between the bearing element 105 and the drilling fluid, a laminar flow results in a mostly conductive heat transfer, and the resulting Nusselt number is in the range of one to ten. When a baffle or other fluid restriction element is utilized in the substrate assembly, increased turbulence in the flow employs much more convective heat transfer, and the resulting Nusselt number is in the range of 100-1000.
[0050] While not limiting to the aforementioned representations, the fluid restriction element can be in the form of a baffle on the bearing element 105, a concave depression or a convex protrusion on the substrate surface 107, or the like. The size, placement, and number of fluid restriction element will determine the extent of the turbulence induced.
[0051] By way of example, the bearing elements 105 may further include one or more baffle to affect the flow of fluid between the bearing elements. The baffle may be a depression or void formed on the exterior of the bearing element 105, or a protrusion extending outward from a surface of the bearing element. The baffle may be on the side 109 of the bearing element so the outwardly exposed bearing element face 111 is smooth and without obstruction.
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[0053] Turning to
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[0056] As shown in
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[0062] In order to achieve preferred bearing assemblies according to the present subject matter, a pneumatic press is utilized to simultaneously seat the bearings into a substrate with an epoxy within 0.001″ of the same plane. This allows for the highest proficiency to achieve a solid and uniform hold while simultaneously seating bearings within 0.001″ of the same plane, which is preferred to achieve proper bearing load distribution.
[0063] An example of a pneumatic press that can be utilized is shown in
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[0066] Thus, provided is a method to manufacture a substrate assembly utilizing a pneumatic press that a solid and uniform hold while simultaneously seating inserts within 0.001″ coplanarity. This is a preferred geometry necessary to achieve proper bearing load distribution and functionality.
[0067] According to the method, an amount of epoxy is placed in each of the recesses in a substrate. Bearing elements are then placed into the epoxy loaded recesses with little to no force to achieve a wet substrate assembly. As used herein the phrases “wet bearing assembly” or “wet substrate assembly” means a substrate assembly in which the epoxy adhering the bearing elements to the substrate has not yet dried.
[0068] The pneumatic press is prepared by first adding a bottom alignment plate to pneumatic press stage, which may be self-centering. The wet substrate assembly is stacked on top of the bottom alignment plate. A special stick resistant separator material, e.g., a sheet of plastic, wax paper, or other non-stick material, is placed on top of the wet substrate assembly to prevent epoxy from adhering to the steel tooling components of the pneumatic press. On top of the separator material, a top alignment plate is placed. The pneumatic press can then be set at a pressure of from 30 to 120 psi. A preferred pressure range is between 60 and 90 psi. For example, the pneumatic press can be set to a pressure of 70 psi.
[0069] If the pneumatic press pressure is below 30 psi during bearing seating, multi-plane bearing elements are met with poor parallelism (+0.020″ out). This also leads to undesirable epoxy thickness compromising holding capabilities leading to bearing failure. Alternatively, when a pressure of greeter than 120 psi is utilized, adverse effects are seen. For example the bearing elements may be chipped or cracked and too much epoxy may be forced out of the recesses in which the bearing elements sit, which leaves behind to thin a layer of epoxy to provide, which leads to bearing assembly failure in use.
[0070] Once staged, the pneumatic press is engaged for about 10 seconds, i.e., from 0-10, from 5-15 or from 8-12 seconds, prior to release. This time period ensures all inserts have seated under the same load to achieve the requisite coplanarity. Once released the entire tooling stack is removed from the pneumatic press and set aside for around 24 hours to ensure proper curing.
EXAMPLE
[0071] An Instron® push out test was conducted to test the ability to join bearing elements formed from a diamond composite material and stainless steel with epoxy or adhesive compositions. For the test, 9 mm×3 mm VERSIMAX® rounds were encapsulated 1mm deep into 17-4 PH stainless steel holders that include an aperture to push the thermally stable rounds through. Three different adhesive compositions were used to create two assemblies with each adhesive composition. One of each pair of assemblies was subjected to a high temperature box furnace cycle (500° C. for 30 minutes) to recreate temperatures reflective of those encountered in the field. Once prepared the assemblies were subjected to pressure from a push out tool, i.e., a 3/16″ steel tip, making contact in the center of the VERSIMAX® round through the aperture in the steel holder. The data collected is presented in table 1 below:
TABLE-US-00001 TABLE 1 Sample Push Out ft Holding Material Taper Test - lbf State 1 620 Loctite 4KM32 0.0010 121.3 NO heat 2 JB Weld 453u38 0.0012 60.8 NO heat 3 620 Loctite 4KM32 0.0009 0.00 500 C.-30 min 4 JB Weld 453u38 0.0015 26.1 500 C.-30 min 5 Omega OB-700 0.0020 93.7 NO heat 6 JB Weld 453u38 0.0006 78.6 No heat 7 Omega OB-700 0.0014 82.3 500 C.-30 min 8 JB Weld 453u38 0.0010 113.8 500 C.-30 min
[0072] As shown from the push-out test results, all of the adhesive formulations were suitable for joining the VERSIMAX® round to stainless steel at room temperature. However, when subjected to heat, the LOCTITE® formulation was not sufficient to maintain adhesion between the VERSIMAX® round and the steel holder. It is understood that the LOCTITE® formulation was not sufficient because it is a glue rather than an epoxy as described herein.
[0073] Although the present subject matter has been described in connection with embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departure from the spirit and scope of the subject matter as defined in the appended claims. For example, although described in relation to bearing assemblies, the principles, compositions, structures, features, arrangements and processes described herein can also apply to other materials, other compositions, other structures, other features, other arrangements and other processes as well as to their manufacture and to other reactor types.
[0074] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations are not expressly set forth herein for sake of clarity.
[0075] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedeol components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled,” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components, and/or wirelessly interactable, and/or wirelessly interacting components, and/or logically interacting, and/or logically interactable components.
[0076] In some instances, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Those skilled in the art will recognize that such terms (e.g., “configured to”) can generally encompass active-state components and/or inactive-state components and/or standby-state components, unless context requires otherwise.
[0077] While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein.
[0078] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.
[0079] Further, throughout the application, descriptions of various embodiments use “comprising” language; however, it will be understood by one of skill in the art, that in some instances, an embodiment can alternatively be described using the language “consisting essentially of” or “consisting of.”
[0080] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “ a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”
[0081] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.
[0082] Those skilled in the art will appreciate that the foregoing specific exemplary processes and/or devices and/or technologies are representative of more general processes and/or devices and/or technologies taught elsewhere herein, such as in the claims filed herewith and/or elsewhere in the present application.
[0083] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[0084] The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
[0085] One skilled in the art will recognize that the herein described components (e.g., operations), devices, objects, and the discussion accompanying them are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific exemplars set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components (e.g., operations), devices, and objects should not be taken as limiting.