Abstract: A segmental hard material insert for a working tool has a planar polycrystalline diamond layer (13) having, in its layer plane, a main cutting element (16, 36) and a contact edge (15) located opposite the main cutting element, with the main cutting element (16, 36) having two, facing outwardly, convex cutting sections (17, 27; 37, 47) and a smooth, facing outwardly, concave transitional region (19; 39, 49) connecting the two convex cutting sections (17, 27; 37, 47), and with the apex (20; 40) of the transitional region (19; 39, 47) being located on a central line of the main cutting element (16; 36).

Abstract: A method of manufacturing a tool component, which is typically a cutting element or a gauge stone in a rotary drill bit, including a layer of ultra-hard abrasive material bonded to a substrate, the layer of ultra-hard abrasive material comprising a pair of opposed end surfaces, an upper surface defined between the end surfaces, and at least one curved and tapered cutting edge defined at the intersection of the respective end surfaces and the upper surface. The respective cutting edges of the tool component and the respective end surfaces leading to the cutting edges are generally wedge-shaped, the upper surface of the layer following generally the same or a similar profile, at least in the region of the cutting edges.

Abstract: A downhole drill bit includes, a body, a plurality of cutters attached to the body, and at least one prefabricated splitter having a proximal portion and at least one distal portion. The proximal portion is encased within the body and the at least one distal portion extends outwardly of the body. Further the at least one distal portion is in operable communication with at least one of the plurality of cutters such that the at least one distal portion bifurcates cuttings cut by the at least one cutter.

Abstract: A bearing element for a rotary, earth boring drag bit effectively reduces an exposure of at least one adjacent cutting element by a readily predictable amount, as well as a depth-of-cut (DOC) of the cutter. The bearing element has a substantially uniform thickness across substantially an entire area thereof. The bearing element also limits the amount of unit force applied to a formation so that the formation does not fail. The bearing element may prevent damage to cutters associated therewith, as well as possibly limit problems associated with bit balling, motor stalling and related drilling difficulties. Bits including the bearing elements, molds for forming the bearing elements and portions of bodies of bits that carry the bearing elements, methods for designing and fabricating the bearing elements and bits including the same, and methods for drilling subterranean formations are also disclosed.

Abstract: A cutting table includes a cutting surface, an opposing surface, a cutting table outer wall, and one or more slots. The cutting table outer wall extends from the circumference of the opposing surface to the circumference of the cutting surface. The slots extend from a portion of the cutting surface to a portion of the cutting table outer wall. The cutting table is leached to form a thermally stable cutting table. One or more slots are positioned in parallel with at least another slot in some embodiments. In some embodiments, the slots are positioned circumferentially around the cutting surface. In some embodiments, at least one slot is backfilled with a backfilling material to increase heat transfer or impact resistance. In some embodiments, the cutting table is coupled to a substrate to form a cutter. The slots are formed either after or during the formation of the cutting table.

Abstract: A cutting table includes a cutting surface, an opposing surface, a cutting table outer wall, and one or more fins. The cutting table outer wall extends from the circumference of the opposing surface to the circumference of the cutting surface. The fins extend from a portion of the cutting surface to a portion of the cutting table outer wall. The cutting table is optionally leached prior to forming the fins. One or more fins are positioned in parallel with at least another fin in some embodiments. In some embodiments, the fins are positioned circumferentially around the cutting surface. In some embodiments, the cutting table is coupled to a substrate to form a cutter. The fins are formed either after or during the formation of the cutting table.

Abstract: A cutter for a fixed cutter drill bit including a substrate and an ultrahard material layer disposed on an end surface of the substrate, the ultra hard material layer having an upper surface opposite the substrate end surface and a peripheral surface such that the upper surface intersects the peripheral surface along a peripheral edge. The peripheral edge continuously increases and decreases in height as measured from a plane perpendicular to a longitudinal axis of the cutter.

Abstract: A drill bit has cutting elements with multiple cutting surface geometries that are positioned so that their cutting profiles overlap, but do not completely contain or engulf one another. The different cutting surface geometries and the specific overlap create a zone of high density in the middle regions of the cutting profiles and low density in the periphery, resulting in a cutting profile that becomes sharper with increasing wear. Such an arrangement is more effective and stable as the drill bit encounters hard and abrasive formation materials. Moreover, cutting elements with larger axial volumes may be combined with cutting elements having smaller axial volumes.

Abstract: An improved cutter for fixed cutter drill bits includes a base portion with a longitudinal axis that extends through a center of the base portion and a cutting face which is generally centered with the base portion. The cutting face has a periphery edge geometry comprising a first arcuate segment and a second arcuate segment spaced apart and arranged opposite each other with linear edge segments disposed there between forming sides of the cutting face. The cutting face spans a maximum edge-to-edge dimension L in a first direction that corresponds to a major axis of the cutting face. The cutting face spans a maximum edge-to-edge dimension W in a second direction, which is perpendicular to the first direction, and W is less than L.

Abstract: A cutting element for a drag-type earth-boring drill bit includes a cutting table with a face including a region that is configured to cut into a formation at a positive back rake angle and to direct formation cuttings, or chips, that have been cut from the earth formation toward the hydraulics of the drill bit. Drill bits may include one or more cutting elements that have been configured in this manner. Such a drill bit may also include a wear pad for limiting the depth to which a cutting element penetrates a surface of a bore hole in an earth formation. Such a wear pad may have a substantially constant thickness.

Abstract: An impact tool that includes an impact body made from a superhard material bonded to a substrate at a non-planer interface, the impact body having a pointed geometry that includes a substantially frustoconical portion between an apex and a base end, the substantially frustoconical portion including a tapered side wall with at least two different, contiguous slopes that together form an interior included angle which is greater than 135 degrees, and with the thickness of the impact body, as measured from the apex to the non-planar interface, being greater than the thickness of the substrate.

Abstract: A cutting element for an earth boring bit, may include a PDC layer having a flat on a periphery thereof, the flat terminating longitudinally at an edge spaced from a cutting face of the PDC layer. A chamfer adjacent to the cutting face desirably has a length that exceeds its depth. A cutting element may additionally include a chamfer along the entire circumference, multiple step-wise, radially adjacent chamfers, and multiple circumferentially spaced portions of the uppermost radius of the PDC layer of the cutting element that each includes a chamfer with an associated flat. Additionally, a cutting element may include a flat terminating at a radial edge with the cutting face of a PDC layer.

Abstract: The present invention relates to a drill bit having a bit body and a plurality of cutters, which are configured to disintegrate earthen formation as the bit body is rotated by a connected drill string. At least some of the cutters have a first and second body, first and second cutting faces and first and second cutting edges. The body is comprised of hard metal. The cutting elements are comprised of superhard material. The orientation of the first cutter body is reversible as to the other components to permit variation in the proximity of the first and second cutting elements.

Abstract: In one aspect of the invention, a fixed bladed drill bit comprises a working surface comprising a plurality of blades converging at a center of the working surface and diverging towards a gauge of the bit. Each blade comprises a plurality of pointed cutting elements and another plurality of shearing cutters. The plurality of shearing cutters comprises a first shearing cutter. The first shearing cutter on each blade tracks the first shearing cutter on other blades along a common circular cutting path.

Abstract: Cutting elements, earth-boring drill bits having such cutting elements and related methods are described herein. In some embodiments, a cutting element for an earth-boring tool may include a diamond table having an indentation in a cutting face thereof and a shaped feature in a substrate at the interface between the diamond table and the substrate, the shaped feature corresponding to the indentation in the cutting face of the diamond table. In further embodiments, a cutting element for an earth-boring tool may include a sacrificial structure positioned within an indentation in a diamond table. In additional embodiments, a method of forming a cutting element may include positioning a sacrificial structure in a mold, positioning a powdered precursor material over the sacrificial structure, and pressing and sintering the powdered precursor material to form a diamond table having an indentation in a cutting face formed by the sacrificial structure.

Abstract: A cutter for a drill bit used for drilling wells in a geological formation includes an ultra hard working surface and a chamfer along an edge of the working surface, wherein the chamfer has a varied geometry along the edge. The average geometry of the chamfer varies with cutting depth. A depression in the shaped working surface is oriented with the varied chamfer and facilitates forming the varied chamfer. A non-planar interface has depressions oriented with depressions in the shaped working surface to provide support to loads on the working surface of the cutter when used.

Abstract: A drill bit for cutting a borehole having a borehole sidewall, corner and bottom, includes a bit body having a bit axis and a rolling cone cutter mounted on the bit body and adapted for rotation about a cone axis. Further, the drill bit includes at least one insert having a base portion secured in the rolling cone cutter and having a cutting portion extending therefrom. The cutting portion of the at least one insert has a cutting surface including at least one flute.

Abstract: A cutting element includes, a gilmoid with a plurality of cutting edges thereon, and at least one support extending from the gilmoid, the at least one support and at least one of the plurality of cutting edges are simultaneously contactable with a surface upon which the cutting element is restable.

Abstract: A drill bit includes a bit body having a face on which two different types of cutting elements are disposed, the first type being cutting elements suitable for drilling at least one subterranean formation and the second type being cutting elements suitable for drilling through a casing bit disposed at an end of a casing or liner string and cementing equipment or other components, if such are disposed within the casing or liner string, as well as cement inside as well as exterior to the casing or liner string. The second type of cutting elements exhibits a relatively greater exposure than the first type of cutting elements, so as to engage the interior of the casing bit and, if present, cementing equipment components and cement to drill therethrough, after which the second type of cutting elements quickly wears upon engagement with the subterranean formation material exterior to the casing bit, and the first type of cutting elements continues to drill the subterranean formation.

Abstract: A rolling cone drill bit includes a cutter element having a cutting portion with a chisel crest and a pilot portion extending beyond the chisel crest. The pilot portion includes a cutting surface that may be generally conical, or form a second chisel crest. The cutting tip of the pilot portion is supported by buttress portions which emerge from and extend beyond the flanks of the chisel crest to provide additional strength and support for the material of the pilot portion that extends beyond the height of the chisel crest.

Abstract: Superabrasive compacts, methods of fabricating such compacts, and drilling tools that may utilize such compacts are disclosed. In one aspect of the present invention, a superabrasive compact includes a substrate and a superabrasive table attached to the substrate. At least one constituent of the superabrasive table exhibits a substantially monotonic distribution of size, concentration, or both in a selected direction of the superabrasive table. In another aspect of the present invention, a method of fabricating a superabrasive article is disclosed. A plurality of particles may be provided that exhibit a substantially monotonic distribution of particle size, concentration, or both in a selected direction. The particles may be subjected to a high-temperature, high-pressure process to consolidate and form a self-supporting body.

Abstract: Methods of evaluating a superabrasive volume or a superabrasive compact are disclosed. One method may comprise exposing a superabrasive volume to beta particles and detecting a quantity of scattered beta particles. Further, a boundary may be perceived between a first region and a second region of the superabrasive volume in response to detecting the quantity of scattered beta particles. In another embodiment, a boundary between a catalyst-containing region and a catalyst-diminished region of a polycrystalline diamond volume may be perceived. In a further embodiment, a boundary may be perceived between a catalyst-containing region and a catalyst-diminished region of a polycrystalline diamond compact. Additionally, a depth to which a catalyst-diminished region extends within a polycrystalline diamond volume of a polycrystalline diamond compact may be measured in response to detecting a quantity of scattered beta particles. A system configured to evaluate a superabrasive volume is disclosed.

Abstract: A cutter for a downhole cutting tool is disclosed. The cutter includes a cutter body having a cutting face, a peripheral sidewall flank, and a base. The base has a recessed channel that extends inwardly from the peripheral sidewall flank and provides an inlet opening therein. A downhole cutting tool employing the cutter is also disclosed. The cutting tool includes a tool body having a cutter face. The tool also includes a cutter body having a cutting face, a peripheral sidewall flank, and a base, the base having a recessed channel that extends inwardly from the peripheral sidewall flank and provides an inlet opening therein. The tool also includes a braze joint between the base and the bonding surface.

Abstract: A cutting element that includes a substrate; and an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material: a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles; wherein the plurality of interconnected diamond particles form at least about 60 to at most about 80% by weight of the polycrystalline diamond material; and wherein the plurality of metal carbide phases represent at least 50% by weight of the plurality of metallic phases is disclosed.

Abstract: Cutters for a drill bit wherein the cutters have at least one groove in a face of a superabrasive table of the cutters. The cutters may also include ribs adjacent to the at least one groove.

Abstract: This invention relates to carbide inserts used on roller cone bits for oil and gas drilling applications as well as for other geological drilling applications, and more specifically, relates to the convex crested insert with deflected wedge surfaces. The insert comprises a cylindrical portion and a crest portion. Said crest portion is composed of a conical crest base, a top surface and two opposing wedge surfaces. Upper ends of the two wedge surfaces are merged smoothly with top surface of the insert. The specific feature of the structure is that top surface of the crest portion is convexed outwardly and forms a smooth curve surface which is higher in the middle and lowers down gradually to each end. Said two wedge surfaces are slant wedge surfaces, so that a width of the top surface and therefore a width of the insert crest are tapered from one end to the other. Advantages of this invention include: 1.

Abstract: Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided.

Abstract: Methods of drilling subterranean formations include coupling at least one bearing block having an initial thickness to a drill bit, engaging a formation with the drill bit within an initial depth of cut range, and reducing the initial thickness of the bearing block by contacting the formation to cause the initial depth of cut range to be at least partially increased. Methods of forming drill bits for drilling subterranean formations include forming at least one rubbing surface of at least one bearing block from at least one material exhibiting a reduced coefficient of friction and coupling the at least one bearing block to the drill bit. Drill bit assemblies include at least one bearing block having a distal portion configured to provide an initial depth of cut range and a base portion configured to provide an increased depth of cut range greater than the initial depth of cut range.

Abstract: In one aspect of the present invention, a high impact resistant tool comprises a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface, the body comprising a substantially pointed geometry with an apex, the apex comprising a curved surface that joins a leading side and a trailing side of the body at a first and second transitions respectively, an apex width between the first and second transitions is less than a third of a width of the substrate, and the body also comprises a body thickness from the apex to the interface greater than a third of the width of the substrate.

Abstract: A bearing block is provided that may be used with a drag bit body or frame to limit depth of cut of cutters on a bit. The bearing block is designed so that it may be interchangeably replaced or repaired without necessitating alteration to a standardized bit frame. The interchangeable bearing block may be used to provide a target depth of cut (TDOC) and/or a selected contact or rubbing area to support weight on bit and limit depth of cut (DOC) for improving drilling performance of a bit. The interchangeable bearing block brings manufacturing selectability by providing a customizable product in terms of depth of cut selection and cutter penetration control for different formations, which is suitable for use with a common bit frame. A rotary drill bit assembly, a unitary cone insert bearing block for a drill bit, and a bit frame are also provided.

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 for a drill bit used in a geological formation includes a shaped ultra hard working surface. The cutter with the shaped working surface is mounted on a drill bit to provide desired cutting characteristics. The shaped working surface provides varied cutting characteristics depending upon the shape, and the characteristics can vary depending upon the depth of the cut.

Abstract: A drill bit for cutting a borehole comprises a bit body including a bit axis. In addition, the drill bit comprises a rolling cone cutter mounted on the bit body. Further, the drill bit comprises a cutter element having a base portion with a diameter and a cutting portion extending therefrom. The cutting portion comprising a first pair of flanking surfaces that taper towards one another to form a first elongate chisel crest, and a second pair of flanking surfaces that taper towards one another to form a second elongate chisel crest that intersects the first elongate chisel crest in top view. The first crest tangent angle at 10% of the diameter measured radially from the central axis on the first elongate chisel crest in profile view is greater than 75° and less than or equal to 90°.

Abstract: A modified cutting element that includes a base portion, an ultrahard layer disposed on the base portion, and at least one modified region disposed adjacent to a cutting face of the cutter. In certain applications, the ultrahard layer includes thermally stable polycrystalline diamond.

Abstract: A cutter for a drill bit used for drilling wells in a geological formation includes an ultra hard working surface and a chamfer along an edge of the working surface, wherein the chamfer has a varied geometry along the edge. The average geometry of the chamfer varies with cutting depth. A depression in the shaped working surface is oriented with the varied chamfer and facilitates forming the varied chamfer. A non-planar interface has depressions oriented with depressions in the shaped working surface to provide support to loads on the working surface of the cutter when used.

Abstract: A drill bit for drilling a borehole in an earth formation. The drill bit has a central longitudinal axis and may be operated by applying at least a rotary motion about the central longitudinal axis and optionally applying longitudinal reciprocal movement to the drill bit so as to exert a percussive force on the borehole bottom. The drill bit has a surface provided with a plurality of shear cutters having a rake surface arranged to induce a scraping movement along the borehole bottom upon application of the rotary motion. The rake surface, during operation, faces the direction of rotation at a back-rake angle of less than 90°, wherein the backrake angle is defined as the angle included between the projection of a line perpendicular to the rake surface on a plane defined by the central longitudinal axis and the direction of the tangential velocity component of the shear cutter and a plane perpendicular to the longitudinal axis.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and to a bit incorporating such cutting element. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: In one aspect of the present invention, a downhole fixed bladed bit comprises a working surface comprising a plurality of blades converging at a center of the working surface and diverging towards a gauge of the bit, at least on blade comprising a cutting element comprising a superhard material bonded to a cemented metal carbide substrate at a non-planer interface, the cutting element being positioned at a positive rake angle, and the superhard material comprising a substantially conical geometry with an apex comprising a curvature.

Abstract: A PDC cutter including a body formed from a substrate material, an ultrahard layer disposed on the body, and a concave cutting face perpendicular to an axis of the body is disclosed. A PDC cutter including a body formed from a substrate material, an ultrahard layer disposed on the body, and a non-planar cutting face perpendicular to an axis of the body, the cutting face including a circumferential concave portion, and an inner protrusion portion is also disclosed.

Abstract: A rolling cone drill bit includes at least one cutter element comprising a base portion and a cutting portion extending from the base portion. The cutting portion includes a cutting surface with an apex defining an extension height and at least one rib extending from the apex toward the base portion. In addition, the at least one rib has a convex outer surface in profile view.

Abstract: A drill bit for cutting a borehole through an earthen formation comprises a bit body having a bit axis. In addition, the drill bit comprises a rolling cone cutter mounted on the bit body and adapted for rotation about a cone axis. Further, the drill bit comprises an insert having a base portion secured in the rolling cone cutter and having a cutting portion extending therefrom, the insert having an initial impact direction. The cutting portion of the insert has a cutting surface comprising a planar surface defining an extension height. Moreover, the cutting portion of the insert comprises an indentation extending at least partially through the upper planar surface, the indentation including a forward facing formation engaging surface and a lower surface defining a depth of the indentation.

Abstract: In one aspect of the present invention, a downhole fixed bladed bit comprises a working surface comprising a plurality of blades converging at a center of the working surface and diverging towards a gauge of the bit, at least on blade comprising a cutting element comprising a superhard material bonded to a cemented metal carbide substrate at a non-planer interface, the cutting element being positioned at a positive rake angle, and the superhard material comprising a substantially conical geometry with an apex comprising a curvature.

Abstract: A drill bit has cutting elements with multiple cutting surface geometries that are positioned so that their cutting profiles overlap, but do not completely contain or engulf one another. The different cutting surface geometries and the specific overlap create a zone of high density in the middle regions of the cutting profiles and low density in the periphery, resulting in a cutting profile that becomes sharper with increasing wear. Such an arrangement is more effective and stable as the drill bit encounters hard and abrasive formation materials. Moreover, cutting elements with larger axial volumes may be combined with cutting elements having smaller axial volumes, resulting in an even more effective drill bit in terms of durability and ability to drill efficiently in hard and abrasive formations.

Abstract: In one aspect of the present invention, a downhole fixed bladed bit comprises a working surface comprising a plurality of blades converging at a center of the working surface and diverging towards a gauge of the bit, at least on blade comprising a cutting element comprising a superhard material bonded to a cemented metal carbide substrate at a non-planer interface, the cutting element being positioned at a positive rake angle, and the superhard material comprising a substantially conical geometry with an apex comprising a curvature.

Abstract: A rolling cone drill bit includes a cutter element having a cutting portion with a chisel crest and a pilot portion extending beyond the chisel crest. The pilot portion includes a cutting surface that may be generally conical, or form a second chisel crest. The cutting tip of the pilot portion is supported by buttress portions which emerge from and extend beyond the flanks of the chisel crest to provide additional strength and support for the material of the pilot portion that extends beyond the height of the chisel crest.

Abstract: A polycrystalline diamond compact (“PDCD”) cutter includes a cylindrical body formed from a substrate material, an ultrahard layer disposed on the cylindrical body, and a cutting face perpendicular to an axis of the cylindrical body, wherein the cutting face includes two or more lobes and wherein the radius of at least one lobe is between 50 and 90 percent of the radius of the cylindrical body. A PDC cutter includes a substrate, and a cutting face perpendicular to an axis of the substrate, wherein the cross-section of the cutting face comprises multiple lobes, and the cross-section of the substrate is substantially circular.

Abstract: In one aspect of the present invention, a downhole fixed bladed bit comprises a working surface comprising a plurality of blades converging at a center of the working surface and diverging towards a gauge of the bit, at least on blade comprising a cutting element comprising a superhard material bonded to a cemented metal carbide substrate at a non-planer interface, the cutting element being positioned at a positive rake angle, and the superhard material comprising a substantially conical geometry with an apex comprising a curvature.

Abstract: An earth-boring bit has a bit body and at least one cone for rotation relative to the bit body. The cone has a gage surface and a nose area separated by a central area. A nose insert is located in the nose area. The nose insert has a barrel located within a hole in the nose area and an outer end protruding from the cone, the outer end has a perimeter that is a plane perpendicular to a barrel axis of the nose insert.

Abstract: A cutting element may include a substrate having a bonding interface region, and an intermetallic bonded diamond (IBD) element bonded to the bonding interface region of the substrate. In some embodiments, the bonding interface region of the substrate may have a non-axi-symmetrical shape and/or may be symmetrical about only one plane or about zero planes. In some embodiments, the bonding interface region of the substrate may have a shape of a tube, a beveled tube, a tube with one or more internal support structures, a scoop, a plow, a concave shape, a honeycombed shape, or other irregular or complex shape.

Abstract: In one aspect of the invention, a tool has a working portion with at least one impact tip brazed to a carbide extension. The carbide extension has a cavity formed in a base end and is adapted to interlock with a shank assembly of the cutting element assembly. The shank assembly has a locking mechanism adapted to interlock a first end of the shank assembly within the cavity. The locking mechanism has a radially extending catch formed in the first end of the shank assembly. The shank assembly has an outer surface at a second end of the shank assembly adapted to be press-fitted within a recess of a driving mechanism. The outer surface of the shank assembly has a coefficient of thermal expansion of 110 percent or more than a coefficient of thermal expansion of a material of the driving mechanism.