Abstract: A device and associated methodology for producing longitudinal components of metal with helical grooves, in particular spiral drill bits or screws, is provided. The method is suited for mass production and improves the cost effectiveness of production. The method includes providing at least one cold forming stage in which a blank is inserted in a guide mold and cold formed in a split mold with at least two movable jaws. The inner wall of the jaws includes at least one section with a contour designed as a negative of the helical grooves. By a heading tool which is movable in axial direction and which engages the free end of the blank positioned in the guide mold, the blank is pressed at least partially through the central opening of the closed split mold. Thus, helical grooves are produced during the contact with the mold contour by plastical cold forming.

Abstract: Drill bit bodies are provided having one portion formed of one composition and a further portion formed of a different composition. The different compositions provide different functional properties to respective portions of the drill bit body. Methods for forming such drill bit bodies are also provided.

Abstract: A reactive foil is used to assemble the components of rock bit cutters and to affix cutting elements to rock bit bodies. A small pulse of localized energy ignites the foil in a fraction of a second to deliver the necessary amount of heat energy to flow solder or braze and form a strong, true metallic joint. The reaction in the foil may be activated using optical, electrical, or thermal sources.

Abstract: A production method for an insertion end, especially for an insertion end of a drilling, chiseling or boring tool, including the following steps: a longitudinal groove is formed in the outer surface of a preferably cylindrical end piece of a blank, whereby the longitudinal groove acquires an open end section on a front face of the end piece. The outer surface of the end piece is surrounded by a die tool that engages into the longitudinal groove outside of its open end section. The open end section is closed in that the surrounded end piece is compressed by means of a stamp acting on the front face. The segmented, multi-component die tool preferably lies flush against the outer surface of the end piece outside of the longitudinal grooves.

Abstract: A rotary drag bit for drilling a subterranean formation includes a plurality of support elements affixed to the bit body, each forming at least a portion of a cutting element pocket. Each of a plurality of cutting elements has a substantially cylindrical body and is at least partially disposed within a cutter pocket. At least a portion of the substantially cylindrical body of each cutting element is directly secured to at least a portion of a substantially arcuate surface of the bit body. At least a portion of a substantially planar surface of each cutting element matingly engages at least a portion of a substantially planar surface of a support element.

Abstract: Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.

Abstract: A method of designing a rotary drill bit includes selecting and positioning a plurality of cutting elements on a rotary drill bit. At least one substantially helically extending feature is selected and positioned to rotationally follow at least one of the plurality of cutting elements, the at least one substantially helically extending feature exhibiting a selected maximum Helical Pitch.

Abstract: A method of fabricating a micro drill, which includes a drill part for machining a hole and a shank part fixed to a motor, the drill part and the shank part being made of different materials. The method includes the steps of forming a drill part-forming powder compact having a recess in one end thereof, and forming a shank part-forming powder compact having a protrusion, the protrusion intended to be fitted into the recess of the drill part-forming powder compact, forming an assembly of the drill part-forming powder compact and the shank part-forming powder compact, with the protrusion fitted into the recess, and simultaneously sintering the assembly of the drill part-forming powder compact and the shank part-forming powder compact.

Abstract: Earth-boring tools include combinations of shearing cutting elements and gouging cutting elements on a blade of the earth-boring tools. In some embodiments, a gouging cutting element may be disposed adjacent to a shearing cutting element on a blade of an earth-boring tool. Methods of forming earth-boring tools include providing such combination of at least one shearing cutting element and at least one gouging cutting element on a blade of an earth-boring tool.

Abstract: A single use intramedullary reamer comprised of a reamer head assembly and a reamer shaft. The reamer head assembly further comprising a series of reamer blades that reside in a series of surface slots that are helically oriented around the cylindrical body. The series of reamer blades are bonded with the cylindrical body through induction bonding.

Abstract: A method of assembling a drill bit with a jack element that includes obtaining a bit body intermediate a shank and a working face, with the working face including a plurality of blades having of at least one cutting element and a receptacle formed proximate a center of the working face. The method further includes attaching a pocket having a central hollow within the receptacle, and securing the jack element within the central hollow with a press fit such that the centerline of the jack element is substantially coaxial with the axis of rotation of the drill bit.

Abstract: An earth-boring bit comprising a bit body is configured at its upper end for connection into a drillstring. A fixed blade depends axially downwardly from the bit body. An axially extending slot is formed in the bit body adjacent the fixed blade. A bit leg is received and retained in the slot by engagement between the slot and correspondingly shaped bit leg, wherein the bit leg cannot be removed from the slot except by axial movement relative to the bit body. A rolling cutter is secured to the bit leg at its lower extent. A fastener secures the bit leg against movement relative to the bit body and extends through oblong apertures in the bit leg and into the bit body, wherein the bit leg can be moved axially relative to the bit body to adjust the projection of the rolling cutter relative to the fixed blade.

Abstract: A tool for use in an abrasive machining process has a body extending along a central longitudinal axis from a first end to a tip end. An abrasive material is located on the tip end. A central recess is formed in the tip end.

Abstract: A hole opener having a hybrid reaming section for reaming subterranean wellbores may include a tubular reamer body having a longitudinal axis and upper and lower ends, a rolling cutter mount coupled to the body, a rolling cutter rotatably coupled to the mount, and a fixed blade coupled to the body adjacent the mount. A method of forming a hybrid reamer tool for downhole use may include providing a tubular stem having couplers on the upper and lower ends, coupling a reamer body having an outer periphery to the stem between the stem upper and lower ends, coupling a rolling cutter mount to the outer periphery of the reamer body, the mount having a rolling cutter rotatably coupled thereto, and coupling a fixed blade to the outer periphery of the reamer body adjacent the rolling cutter mount.

Abstract: Earth-boring drill bits include a bit body including a blockage-resistant internal fluid passageway. The blockage-resistant internal fluid passageway includes at least one internal fluid passageway formed in the bit body and a cuttings filtering feature formed in the at least one internal fluid passageway configured to prevent at least some cuttings from flowing through the at least one internal fluid passageway. In one embodiment, the cuttings filtering feature includes at least one lateral member extending transversely across the at least one internal fluid passageway. In another embodiment, the cuttings filtering feature includes forming a central portion of the at least one internal fluid passageway with a width along a lateral axis thereof less than an average width of a fluid path extending through a nozzle disposed at least partially within the at least one internal fluid passageway. Methods of forming the blockage-resistant internal fluid passageway are also disclosed.

Abstract: A method for making drill bits includes sequentially moving a plurality of drill bits through a belt furnace, and moving the drill bits to a cooling station using an automated device after the drill bits have moved through the belt furnace. A continuous process for making core drill bits may also include placing a drill bit on a belt of a belt furnace, transporting the drill bit through the furnace using the belt, removing the drill bit from the belt using an automated process, and cooling the drill bit.

Abstract: A downhole tool having a layer of wear resistant material applied thereon utilizing a thermal spray process and methods of manufacturing such downhole tools.

Abstract: Earth-boring drill bits include a bit body, an erosion-resistant extension, and a shank. The erosion-resistant extension includes a generally tubular body, and an erosion-resistant material lining the generally tubular body within a fluid passageway. The erosion-resistant material lining the generally tubular body within the fluid passageway exhibits an erosion resistance greater than an erosion resistance exhibited by a material of the generally tubular body. Methods of forming an erosion-resistant extension include lining at least a portion of a wall of a generally tubular body within a fluid passageway extending through the generally tubular body with an erosion-resistant material.

Abstract: A method of manufacturing a roller cone drill bit may include forming a body of a single piece having an upper end and a lower end; machining at the lower end of the body at least two journals extending downward and radially outward from a central axis of the body; machining at least one of a ball passage, a hydraulic fluid passageway, a grease reservoir, and a lubricant passageway; and mounting roller cones on the at least two journals.

Abstract: A drill having a drill head (11) made of hard metal and a shaft (12) or a coupling piece (16) made of a sintered iron alloy. The hard metal is joined in the form of a material connection to the sintered iron alloy by a sintering process.

Abstract: Casing bits include an expander for enlarging an inner diameter of expandable casing at least partially disposed within a body of the casing bits. Drilling assemblies include a casing bit attached to an end of expandable casing, and an expander disposed in proximity to the casing bit and a distal end of the expandable casing. Methods of forming casing bits include positioning an expander in proximity to a body of a casing bit. Methods of forming drilling assemblies include positioning an expander in proximity to a body of a casing bit and a distal end of expandable casing, and attaching the casing bit to the end of the expandable casing. Methods of casing a wellbore include one or both of drilling and reaming a wellbore using a casing bit attached to a distal end of expandable casing, and forcing an expander through the expandable casing.

Abstract: A back reamer includes a drive stem configured to support a main reamer body, the main reamer body including a plurality of receptacles, and a plurality of cutting leg assemblies in positive locking engagement with the plurality of receptacles to restrict radial movement of the cutting leg assemblies.

Abstract: Cutter assemblies comprising an outer support element and a cutting element disposed therein. The cutting element is immovably attached to the outer support element. Also provided are downhole tools incorporating such cutter assemblies and methods of making such downhole tools.

Abstract: A rock bit is formed with pockets for enhanced cutting element retention and support of cutting elements during operation of the rock bit. Portions of the pockets are carburized to increase a yield strength of the pockets, which also increases the retention of the cutting elements. The pockets are formed at a diameter that is slightly smaller than an outer diameter of the cutting elements. Portions of the pockets are then carburized. The pockets are heated until the diameter of the pockets is equal to the outer diameter of the cutting elements. After the rock bit has been cooled and cleaned, a material is placed in each pocket prior to installing the cutting elements. The material homogenizes support for the cutting elements during operation of the rock bit.

Abstract: A method and system for manufacturing a earth boring tool, comprising placing a tool in a positioner of an system which then conforms the tool to a model through the performance of a plurality of processing steps thereon. The positioner may move the tool in two axis. The system may include a manipulator which performs each of the processing steps. Alternatively, the system may include a plurality of manipulators, each performing a different one of the processing steps. The processing steps may include various shaping, cleaning, painting, and packaging steps. The processing steps may be performed without removing the tool from the positioner. The tool may be repositioned in the positioner during or between processing steps. For example, performing the processing steps may comprise performing one or more of the process steps, repositioning the tool in the positioner, and re-performing the one or more of the process steps.

Abstract: A rotary drill bit (10) is provided for drilling a hole in a subsurface formation. The bit body (12) includes a plurality of axially extending ribs (16a, b, c and d) and a flow channel between adjacent ribs. A plurality of cutting elements (19) are fixedly mounting on a respective one of the plurality of ribs. A plurality of flow nozzles (20a, b, c and d) direct fluid to a respective one of the plurality of cutting elements to clean and cool the cutting elements.

Abstract: A method of making a drill bit having the following steps: placing matrix material in a bit body mold; placing a metal blank in the bit body mold; placing a binder material in the bit body mold with the binder material proximate the matrix material and the metal blank; and exposing hinder material to microwave radiation, whereby hinder material and other constituents is heated to a selected temperature to allow hinder material to melt and to infiltrate matrix material. A method of heating selected portions of a drill bit comprising: placing the drill bit in an insulative oven having a wave guide of microwave radiation from a microwave generator; positioning a portion of the drill bit to be heated proximate the wave guide; and exposing the portion of the drill bit to be heated to microwave radiation, wherein the portion of the drill bit is heated without overheating remaining portions of the drill bit.

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: A drilling tool including a tool body and a cutter pocket formed in the tool body, the cutter pocket including a front planar surface, a back planar surface opposite the front planar surface, a first side surface between the front and back planar surfaces, and a second side surface opposite the first side surface and between the front and back planar surfaces is disclosed herein. A method of manufacturing a drilling tool including machining a tool body having a cutter pocket in accordance with embodiments disclosed herein, disposing a cutting element in the cutter pocket, and brazing the cutting element in the cutter pocket is disclosed.

Abstract: Earth-boring drill bits include a bit body, an element having an attachment feature bonded to the bit body, and a shank assembly. Methods for assembling an earth-boring rotary drill bit include bonding a threaded element to the bit body of a drill bit and engaging the shank assembly to the threaded element. In additional embodiments, a nozzle assembly for an earth-boring rotary drill bit may include a cylindrical sleeve having a threaded surface and a threaded nozzle disposed at least partially in the cylindrical sleeve and engaged therewith. Methods of forming an earth-boring drill bit include providing a nozzle assembly including a tubular sleeve and nozzle at least partially within a nozzle port of a bit body.

Abstract: Methods of forming and repairing earth-boring tools include providing wear-resistant material over a temporary displacement member to form a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature is configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: A helical reamer for reaming a bone cavity has a longitudinally extending support shaft having a first driven end and a second end having a tip for insertion into the bone cavity. The research for a multiplicity of stamped flat reamer plates each having a plurality of cutting flutes formed on an external surface thereof and a central internal opening to receive the support shaft. The internal opening includes a coupling element in the form of a key and keyway rotationally coupling each reamer plate to the support shaft. The key and keyway allowing each reamer plate to be slightly rotated with respect to the flutes of an adjacent reamer plate. The coupling elements for rotationally coupling the plates to the drive shaft can be mating flattened areas on the internal surface of the stamping and the external surface of the drive shaft. A broach of stamped plates is also shown.

Abstract: A method of constructing an earth-boring, diamond-impregnated drill bit has a first step of coating diamond grit with tungsten to create tungsten-coated diamond particles. These coated particles are then encapsulated in a layer of carbide powder held by an organic green binder material. The encapsulated granules are then mixed along with a matrix material and placed in a mold. The matrix material includes a matrix binder and abrasive particles. The mixture is heated in the mold at atmospheric pressure to cause the matrix binder to melt and infiltrate the encapsulated granules and abrasive particles.

Abstract: Embodiments of the present invention include a drill bit configured for boring holes or wells into the earth. Embodiments include a drill bit comprised of a plurality of blades. A first plurality of the blades has cutting elements positioned substantially within the cone section of the drill bit. A second plurality of blades has cutting elements positioned substantially within the blade flank section and the blade shoulder section. Another embodiment of the first plurality of blades in which the blades end or truncate at a radial distance substantially less than the radial distance of the blade shoulder section from the center of the drill bit.

Abstract: A cutting element for use with an earth boring drill bit includes a diamond cutting table that is substantially free of a metallic binder. The cutting table may include polycrystalline diamond and a carbonate binder or polycrystalline diamond with silicon and/or silicon carbide dispersed therethrough. A base of the cutting table is secured to a substrate by way of an adhesion layer. The adhesion layer includes diamond. The adhesion layer may also include cobalt or another suitable binder material, which may be mixed with diamond particles from which the adhesion layer is formed, or may leach from the substrate into the adhesion layer as the cutting element is bonded to the substrate. Alternatively, the cutting table may be formed from and consist essentially of chemical vapor deposited diamond that has been diamond bonded to an underlying polycrystalline diamond compact. Processes for securing substantially metallic binder-free cutting elements to substrates are also disclosed.

Abstract: Earth-boring tools such as, for example, earth-boring rotary drill bits include erosion-resistant structures disposed proximate areas of intersection between faces of the tools and fluid nozzle recesses or fluid passageways extending through the tools to the face. In some embodiments, such an erosion-resistant structure may comprise a mass of hardfacing material. In additional embodiments, such an erosion-resistant structure comprises an erosion-resistant insert. Methods of forming such earth-boring tools include providing erosion-resistant structures proximate intersections between the faces of the tools and fluid nozzle recesses or fluid passageways extending through the tools. Methods of repairing earth-boring tools include providing an annular-shaped, erosion-resistant structure over an eroded surface of a body of a previously used earth-boring tool proximate an intersection between an outer face of the body and an inner surface of the body.

Abstract: A drill bit is disclosed that in one configuration may include at least one cutter on a face section of the bit and at least one opening proximate the at least one cutter configured to discharge fluid under pressure onto the formation to create a fluid cushion between the drill bit and the formation during a drilling operation. An actuation device associated with the drill bit may be utilized to provide fluid under pressure to the at least one opening.

Abstract: A low cost disposable reamer shaft is made from a rod or tube stock of stainless steel, Nitinol or fiber reinforced polymer having a precise outer diameter in the range of 4 to 14 millimeter and is cut to a shaft length of 250 to 400 millimeters. An attachment piece with male or female thread matching a spherical hollow or tapered hollow reamer is machined and glued with epoxy on one end of the rod of tube stock using a precision centerline aligning jig. An attachment piece for connecting to a drive power unit is machined and glued with epoxy to the other end of the rod or tube stock thus forming a low cost disposable reamer shaft that aligns the centerline of the shaft with that of the reamer. The shaft contacts the reamer at two attachment locations that are displaced from each other, providing precise centerline alignment.

Abstract: An indexable insert for drilling includes front and rear edges opposite to each other and having a rotationally symmetrical relation; and two side surfaces opposite to each other and having a rotationally symmetrical relation. Each side surface has first and second cutting edge portions formed thereon. The first cutting edge portion is disposed farther than the second cutting edge from the center of the blank insert, thereby providing a step between the first and second cutting edge. The first cutting edge is adjacent to the front edge.

Abstract: A drill bit that includes a steel bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; at least one recess formed in at least a portion of the surface of the at least one cutter pocket, wherein the recess is adjacent a leading face of the at least one blade; and an erosion resistant material in the at least one recess is disclosed.

Abstract: A method for forming a nozzle retention body suitable for engagement to a drill bit includes manufacturing an unfinished nozzle retention body which includes an upper end and a lower end. The upper end forms an inlet that transitions into a flowbore. The lower end has a nozzle receptacle passage machined therein toward the flowbore at an angle with respect to the lower end of the flowbore.

Abstract: An endodontic reamer and a method for manufacturing endodontic reamers and files, more specifically an endodontic reamer having a cylindrical shaft and a working portion extending forward from a removed end of the shaft. The working portion includes, typically, a pair of wedged shaped projecting sections that extend beyond the diameter of the shaft. Forward from the wedge shaped sections is a nose, typically non-cutting nose, that has a diameter of about equal to diameter of the shaft. There are typically two (2) wedge shaped sections projecting outward opposite one another. Applicant also provides a novel method for manufacturing an endodontic reamer, which consists of using a two piece mold and placing a wire blank between the mold, followed by forcing the mold together, under compression, against the wire blank, to deform the blank into the shape of the mold parts.

Abstract: Core drill bits with long crown heights are described herein. The core drill bits have a series of slots or openings that are not located at the tip of the crown and are therefore enclosed in the body of the crown. The slots may be staggered and/or stepped throughout the crown. As the cutting portion of the drill bit erodes through normal use, the fluid/debris notches at the tip of the bit are eliminated. As the erosion progresses, the slots become exposed and then they function as fluid/debris ways. This configuration allows the crown height to be extended and lengthened without substantially reducing the structural integrity of the drill bit.

Abstract: A method of manufacturing a milling cutter having a cutting head and a coaxial integral shank comprising the steps of grinding, in a first grinding operation, a plurality of helical flutes (5) into the outer periphery of a cutter blank from a lead end (24) using a peripheral area (16) of a first grinding wheel (15) generally of frusto-conical profile and rotatable about an axis (18) generally transversely of the milling cutter axis (1), which peripheral area (16) produces, simultaneously, the following three features: a leading face (9) of a trailing tooth; a rear face (10) on an adjacent preceding tooth; and a swarf removal gullet (13) having divergent sides, grinding, in a second grinding operation, and using a peripheral edge (19) of a second grinding wheel (20), a relief face (11), which extends rearwardly from a leading end of a tooth tip, resulting in a minimum tooth wedge angle of approximately 60°, and grinding, in a third grinding operation, a radius (23) on the end of each flute.

Abstract: A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB2 in exemplary embodiments.

Abstract: A shank configuration for rotary drill bits is disclosed for positioning of the shank in relation to the bit body. A tapered surface or feature of the shank may be configured and sized to matingly engage a complementarily shaped surface or feature of the drill bit body and thereby become centered or positioned in relation thereto. A deformable element may be disposed between the shank and bit body. Also, the shank may comprise a material having a carbon equivalent of less than about 0.35%. A multi-pass weld procedure may be employed to affix the shank and bit body to one another wherein welds may be formed so that one weld originates at a circumferential position that differs from the origination circumferential position of its immediately preceding weld by at least about 90°. Further, a stress state may be developed within the multi-pass weld. A method of manufacture is also disclosed.

Abstract: A polycrystalline superabrasive composite tool can be produced using high pressure high temperature processes allowing for increased thermal resistance, wear resistance and toughness of abrasive tools, and additionally allowing for increased effective thickness of abrasive tools. A polycrystalline superabrasive compact can include a support substrate and a superabrasive polycrystalline layer having a diffusion bridge embedded therein that includes a carbide former. Additionally, a working layer can be attached adjacent to the superabrasive polycrystalline layer and opposite the support substrate to form a drill bit sandwich segment. The diffusion bridge matrix of the present invention allows for a new welding phase at each interface between the superabrasive polycrystalline layer and support substrate and between the polycrystalline layer and the metal working layer, thus eliminating delamination failure at the interfaces.

Abstract: A drill bit including at least one stress-relieved cutting element, wherein the at least one cutting element is mounted on the drill bit, wherein the stress-relieved cutting element includes a substrate, at least one transition layer disposed upon the substrate and a polycrystalline diamond layer having a thickness of at least 0.008 inches disposed upon the at least one transition layer.

Abstract: A method for making drill bits includes sequentially moving a plurality of drill bits through a belt furnace, and moving the drill bits to a cooling station using an automated device after the drill bits have moved through the belt furnace. A continuous process for making core drill bits may also include placing a drill bit on a belt of a belt furnace, transporting the drill bit through the furnace using the belt, removing the drill bit from the belt using an automated process, and cooling the drill bit.

Abstract: A method and apparatus for treating a cutter ring adapted to be used in tunnel boring operations; forming an initial cutter ring and heat treating the cutter ring prior to a laser client process; applying an alloy to the surface of the cutter ring adjacent to cutting elements by a laser cladding process whereby the cutting elements have insufficient heat transfer from the laser cutting process to reduce their hardness properties.