Abstract: A drill bit includes a bit body having an end face for engaging a rock formation. The end face is defined by a HIP pressed center structure formed of a metal matrix impregnated with super abrasive particles. The HIP pressed center structure includes a central region located at a center axis of said drill bit and finger regions extending radially from the central region. The end face is further defined by infiltrated ribs formed of a metal matrix impregnated with super abrasive particles. Certain ones of the infiltrated ribs are configured to form radial extensions from the finger regions of the HIP pressed center structure.

Abstract: An apparatus and method for manufacturing a downhole tool that reduces failures occurring along a bondline between a cemented matrix coupled around a blank. The cemented matrix material is formed from a tungsten carbide powder, a shoulder powder, and a binder material, wherein at least one of the tungsten carbide powder or the shoulder powder is absent of any free tungsten. The blank, which optionally may be coated, is substantially cylindrically shaped and defines a channel extending from a top portion and through a bottom portion of the blank. The absence of free tungsten from at least one of the tungsten carbide powder or the shoulder powder reduces the reaction with iron from the blank, thereby allowing the control and reduction of intermetallic compounds thickness within the bondline.

Abstract: An apparatus and method for manufacturing a downhole tool that reduces failures occurring along a bondline between a cemented matrix coupled around a blank. The cemented matrix material is formed from a powder and a binder material. The blank includes an internal blank component and a coating coupled around at least a portion of the surface of the internal blank component. The internal blank component includes a top portion and a bottom portion. The internal blank component is substantially cylindrically shaped and defines a channel extending through the top portion and the bottom portion. The coating is a metal in some exemplary embodiments. The coating reduces the migration of the binder material into the blank thereby allowing the control of intermetallic compounds thickness within the bondline.

Abstract: A cutter is configured with a diamond table made from a thin hard facing material layer of polycrystalline diamond bonded to a backing layer made from cemented tungsten carbide. The face of the diamond table includes a concavity formed with a curved shape wherein at least a portion of the face in a center of the cutter is recessed with respect to at least some portion of the face about the perimeter of the cutter. This concave curved shape is formed in the diamond table itself such that the diamond table has a varying thickness depending on the implemented concavity.

Abstract: A self positioning cutter element and cutter pocket for use in a downhole tool having one or more cutting elements. The self positioning cutter element includes a substrate and a wear resistant layer coupled to the substrate. The cutter element includes a cutting surface, a coupling surface, and a longitudinal side surface forming the circumferential perimeter of the cutter element and extending from the cutting surface to the coupling surface. The cutter element has one or more indexes formed on at least a portion of the coupling surface. In some embodiments, the index also is formed on at least a portion of the longitudinal side surface. Hence, the coupling surface is not substantially planar. Additionally, at least a portion of the longitudinal side surface does not form a substantially uniform perimeter. The cutter pocket also is indexed to correspond and couple with the indexing of the cutter element.

Abstract: A self positioning cutter element and cutter pocket for use in a downhole tool having one or more cutting elements. The self positioning cutter element includes a substrate and a wear resistant layer coupled to the substrate. The cutter element includes a cutting surface, a coupling surface, and a longitudinal side surface forming the circumferential perimeter of the cutter element and extending from the cutting surface to the coupling surface. The cutter element has one or more indexes formed on at least a portion of the coupling surface. In some embodiments, the index also is formed on at least a portion of the longitudinal side surface. Hence, the coupling surface is not substantially planar. Additionally, at least a portion of the longitudinal side surface does not form a substantially uniform perimeter. The cutter pocket also is indexed to correspond and couple with the indexing of the cutter element.

Abstract: A cutter is configured with a diamond table made from a thin hard facing material layer of polycrystalline diamond bonded to a backing layer made from cemented tungsten carbide. The face of the diamond table includes a concavity formed with a curved shape wherein at least a portion of the face in a center of the cutter is recessed with respect to at least some portion of the face about the perimeter of the cutter. This concave curved shape is formed in the diamond table itself such that the diamond table has a varying thickness depending on the implemented concavity.

Abstract: A cutter is configured with a diamond table made from a thin hard facing material layer of polycrystalline diamond bonded to a backing layer made from cemented tungsten carbide. The face of the diamond table includes a concavity formed with a curved shape wherein at least a portion of the face in a center of the cutter is recessed with respect to at least some portion of the face about the perimeter of the cutter. This concave curved shape is formed in the diamond table itself such that the diamond table has a varying thickness depending on the implemented concavity. Alternatively, the concave curved shape is formed in the backing layer and a substantially constant thickness diamond table layer is attached thereto.

Abstract: A PDC cutter utilizes the combination of an elliptical shape with higher thermal resistance obtained through leaching to provide a cutter which is more effective than a cutter using either concept alone. The PDC cutter includes a tungsten carbide portion with protrusions extending from a surface thereof in a pattern. The diamond volume is mounted to the surface wherein the protrusions allow for the diamond volume to be larger about a perimeter edge of the cutter and smaller/shallower in a center region of the cutter. The protrusions providing surfaces for the diamond layer (table) to bond to the underlying tungsten carbide portion. With this configuration, diamond volume is maximized around the edge of the cutter.

Abstract: A cutting element for a drag-type drill bit comprises a cutter body having a generally cylindrical base section adapted for snug-fitting engagement in a socket of a drill bit body. The cutter body is secured to the bit body by brazing or other conventional attachment techniques. The cutter body further has a generally cylindrical cutting section integral with the base section. The cutting section has at least one inclined surface extending from a top surface of the cutting section partially along the length of the generally cylindrical cutting section. The cutter body may comprise a sintered tungsten carbide and the top surface may comprise a layer of super hard material.

Abstract: A cutting element for a drag-type drill bit comprises a cutter body having a generally cylindrical base section adapted for snug-fitting engagement in a socket of a drill bit body. The cutter body is secured to the bit body by brazing or other conventional attachment techniques. The cutter body further has a generally cylindrical cutting section integral with the base section. The cutting section has at least one inclined surface extending from a top surface of the cutting section partially the length of the generally cylindrical cutting section. The cutter body may comprise a sintered tungsten carbide and the top surface may comprise a layer of super hard material.

Abstract: A method for creating a rapid prototype mold for parts of an earth boring tool for manufacture thereof comprises initially optimizing the drill bit design and integrating this design into CAD code. The CAD code is utilized to generate a prototype file in a computer outputting command signals to a laser, and a laser scanner to prototype a mold utilizing stereolithography, selective laser sintering, or laminated object manufacturing, in addition to other prototype techniques to manufacture earth boring tool parts.

Abstract: A method and system for engineering a drilling bit program linked to rock removal at a cutting element/formation interface and specific to drilling of one or more wells in a given geographic area is disclosed. The system includes a first arrangement for planning the drilling of a particular well based upon a cascaded planning input and providing an engineered output which is a function of the cascaded planning input, wherein a level of the engineered output being dependent upon a level of the cascaded planning input. A second arrangement is provided for implementing the engineered output in the drilling of the particular well is also provided. Lastly, a third arrangement is provided for evaluating the implementation of the engineered output for the drilling of the particular well and providing an evaluation output. The evaluation output can be used by the planning arrangement as additional planning input for planning the drilling of a subsequent well in the geographic area.