Abstract: Methods of evaluating prototype cutting elements for earth-boring tools may involve generating first and second sets of virtual representations of cutting elements from first and second sets of used cutting elements. First and second sets of measures of damage corresponding to damage for each of the first and second sets set of virtual representations of cutting elements may be determined. A best-performing set of cutting elements from the first and second sets of used cutting elements according to the first and second sets of measures of damage may be identified by performing a statistical analysis.

Abstract: A hardfacing material includes a metal matrix material and particles of crushed polycrystalline diamond material embedded within the metal matrix material. An earth-boring tool includes a body comprising particles of fragmented polycrystalline diamond material embedded within a metal matrix material. The particles of fragmented polycrystalline diamond material include a plurality of inter-bonded diamond grains. A method includes forming an earth-boring tool including a metal matrix material and particles of crushed polycrystalline diamond material.

Abstract: Cutting structures for use with downhole tools in subterranean boreholes include a blade, a plurality of primary cutting elements coupled to the blade, and at least one secondary element rotationally leading the plurality of primary cutting elements in a direction of intended rotation of the cutting structure. The at least one secondary element is coupled to the blade proximate a leading surface of the blade and comprises at least one of a rubbing surface and a cutting surface. An exposure of at least one primary cutting element of the plurality of primary cutting elements is greater than an exposure of the at least one secondary element. Downhole tools such as reamers include cutting structures. Methods of enlarging a subterranean borehole include reaming a borehole with cutting structures.

Abstract: Methods of forming a polycrystalline table may involve disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles may be partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate may be removed from the brown polycrystalline table and catalyst material may be removed from the brown polycrystalline table. The brown polycrystalline table may then be fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate may include a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table may include a plurality of interbonded grains of a superabrasive material.

Abstract: Cutting structures for use with downhole tools in subterranean boreholes include a blade, a plurality of primary cutting elements coupled to the blade, and at least one secondary element rotationally leading the plurality of primary cutting elements in a direction of intended rotation of the cutting structure. The at least one secondary element is coupled to the blade proximate a leading surface of the blade and comprises at least one of a rubbing surface and a cutting surface. An exposure of at least one primary cutting element of the plurality of primary cutting elements is greater than an exposure of the at least one secondary element. Downhole tools such as reamers include cutting structures. Methods of enlarging a subterranean borehole include reaming a borehole with cutting structures.

Abstract: A cutting element for an earth-boring tool. The cutting element comprises a substrate base, and a volume of polycrystalline diamond material on an end of the substrate base. The volume of polycrystalline diamond material comprises a generally conical surface, an apex centered about a longitudinal axis extending through a center of the substrate base, a flat cutting surface extending from a first point at least substantially proximate the apex to a second point on the cutting element more proximate a lateral side surface of the substrate base. Another cutting element is disclosed, as are a method of manufacturing and a method of using such cutting elements.

Abstract: A cutting element for an earth-boring tool includes at least one volume of superabrasive material on a substrate. The volume of superabrasive material includes a first planar surface and a second planar surface oriented at an angle relative to the first planar surface and intersecting the first planar surface along an apex. The first planar surface has a circular or oval shape having a first maximum diameter, and the second planar surface has a circular or oval shape having a second maximum diameter. The apex has a length less than the first maximum diameter and the second maximum diameter. Earth-boring tools include such a cutting element attached to a body. Methods of forming earth-boring tools include the attachment of such a cutting element to a body of an earth-boring tool.

Abstract: Methods of forming a polycrystalline table may involve disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles may be partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate may be removed from the brown polycrystalline table and catalyst material may be removed from the brown polycrystalline table. The brown polycrystalline table may then be fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate may include a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table may include a plurality of interbonded grains of a superabrasive material.

Abstract: Cutting elements for an earth-boring tool include a substrate base and a cutting tip. The cutting tip may include a first generally conical surface, a second, opposite generally conical surface, a first flank surface extending between the first and second generally conical surfaces, and a second, opposite flank surface. The cutting tip may include a central axis that is not co-linear with a longitudinal axis of the substrate base. The cutting tip may include a surface defining a longitudinal end thereof that is relatively more narrow in a central region thereof than in a radially outer region thereof. Earth-boring tools include a body and a plurality of such cutting elements attached thereto, at least one cutting element oriented to initially engage a formation with the first or second generally conical surface thereof. Methods of drilling a formation use such cutting elements and earth-boring tools.

Abstract: A cutting element for an earth-boring tool includes at least one volume of superabrasive material on a substrate. The volume of superabrasive material includes a first planar surface and a second planar surface oriented at an angle relative to the first planar surface and intersecting the first planar surface along an apex. The first planar surface has a circular or oval shape having a first maximum diameter, and the second planar surface has a circular or oval shape having a second maximum diameter. The apex has a length less than the first maximum diameter and the second maximum diameter. Earth-boring tools includes such a cutting element attached to a body. Methods of forming earth-boring tools include the attachment of such a cutting element to a body of an earth-boring tool.

Abstract: Methods of forming a polycrystalline table may involve disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles may be partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate may be removed from the brown polycrystalline table and catalyst material may be removed from the brown polycrystalline table. The brown polycrystalline table may then be fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate may include a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table may include a plurality of interbonded grains of a superabrasive material.

Abstract: Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

Abstract: Cutting elements for an earth-boring tool include a substrate base and a cutting tip. The cutting tip may include a first generally conical surface, a second, opposite generally conical surface, a first flank surface extending between the first and second generally conical surfaces, and a second, opposite flank surface. The cutting tip may include a central axis that is not co-linear with a longitudinal axis of the substrate base. The cutting tip may include a surface defining a longitudinal end thereof that is relatively more narrow in a central region thereof than in a radially outer region thereof. Earth-boring tools include a body and a plurality of such cutting elements attached thereto, at least one cutting element oriented to initially engage a formation with the first or second generally conical surface thereof. Methods of drilling a formation use such cutting elements and earth-boring tools.

Abstract: Partially formed earth-boring rotary drill bits comprise a first less than fully sintered particle-matrix component having at least one recess, and at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess. Each less than fully sintered particle-matrix component comprises a green or brown structure including compacted hard particles, particles comprising a metal alloy matrix material, and an organic binder material. The at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of organic binder material from the less than fully sintered particle-matrix components in a sintering process to be used to sinterbond the first less than fully sintered particle-matrix component to the first less than fully sintered particle-matrix component.

Abstract: Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

Abstract: A hardfacing material includes a metal matrix material and particles of crushed polycrystalline diamond material embedded within the metal matrix material. An earth-boring tool includes a body comprising particles of fragmented polycrystalline diamond material embedded within a metal matrix material. The particles of fragmented polycrystalline diamond material include a plurality of inter-bonded diamond grains. A method includes forming an earth-boring tool including a metal matrix material and particles of crushed polycrystalline diamond material.

Abstract: Earth-boring drill bits may include a bit body including blades extending radially over a face of the earth-boring drill bit and cutting elements attached to each blade. Only cutting elements including planar cutting faces may be attached to at least one of the blades. Only cutting elements including nonplanar cutting faces may be attached to at least another of the blades. Only cutting elements including planar cutting faces or only cutting elements including nonplanar cutting faces may be attached to each of the blades. Only cutting elements including nonplanar cutting faces may be attached to a number of the blades that may be unequal to a number of the blades to which only cutting elements comprising planar cutting faces may be attached.

Abstract: Partially formed earth-boring rotary drill bits comprise a first less than fully sintered particle-matrix component having at least one recess, and at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess. Each less than fully sintered particle-matrix component comprises a green or brown structure including compacted hard particles, particles comprising a metal alloy matrix material, and an organic binder material. The at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of organic binder material from the less than fully sintered particle-matrix components in a sintering process to be used to sinterbond the first less than fully sintered particle-matrix component to the first less than fully sintered particle-matrix component.

Abstract: Cutting elements include a volume of superabrasive material. The volume of superabrasive material comprises a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. An earth-boring tool may comprise a bit body and at least one cutting element attached to the bit body. Methods of forming cutting elements comprise forming a volume of superabrasive material comprising forming a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. Methods of forming earth-boring tools comprise forming a cutting element and attaching the cutting element to an earth-boring tool.

Abstract: A cutting element for an earth-boring tool. The cutting element comprises a substrate base, and a volume of polycrystalline diamond material on an end of the substrate base. The volume of polycrystalline diamond material comprises a generally conical surface, an apex centered about a longitudinal axis extending through a center of the substrate base, a flat cutting surface extending from a first point at least substantially proximate the apex to a second point on the cutting element more proximate a lateral side surface of the substrate base. Another cutting element is disclosed, as are a method of manufacturing and a method of using such cutting elements.