Abstract: A nozzle retention receptacle for rotary cone rock bits consists of a nozzle retention receptacle body forming a fluid passage therethrough. The body forms a first upstream entrance end that forms part of a wall of a plenum formed within a rock bit body and a second downstream exit end. The upstream end further forms a mounting interface that circumvents a fluid entrance port to the passage in the nozzle retention receptacle. The port communicates with the fluid plenum in the bit body. The body of the rock bit further forms a nozzle retention receptacle mounting interface that is common to the mounting interface formed by the nozzle retention receptacle.

Abstract: A two trip sidetrack casing milling apparatus for elongating and enlarging a previously formed window in a cased borehole in preparation for a subsequent sidetracking drilling operation is disclosed. The apparatus consists of three mills on a shaft, a first window mill is secured to an end of a shaft. The first window mill forms a diameter larger than a diameter of a subsequent sidetracking drill bit that is passed through the window. A second pilot mill is secured to the shaft and strategically positioned above the first window mill. The second pilot mill forms a diameter that is less than the diameter of the first window mill. A third watermelon mill is secured to the shaft and strategically positioned above the second pilot mill. The third watermelon mill forms a diameter that is at least the same diameter as the first window mill.

Abstract: A radially disposed thrust bearing assembly for air cooled and lubricated mining type rotary cone rock bits consists of a first non-rotating radially disposed steel thrust bearing disc and an apposed, non-rotating carbide thrust bearing disc. One of the thrust bearing discs is pressed into a disc retention socket formed in the end of a spindle bearing extending from the end of a main axially aligned bearing cantilevered from a leg of the bit and the other thrust bearing disc is pressed into a disc retention socket formed in the rotary cone. An edge of the carbide disc is formed with large valleys and peaks, the robust undulations resist cracking when the carbide thrust bearing disc is pressed into its respective socket. Unique air passages and channels are formed in the main and spindle bearings to direct cooling air to the apposed thrust bearing discs.

Abstract: A rotary cone rock bit for use in earthen formations with drilling fluid hydraulics wherein diffusion type nozzles are utilized in the outer diameters of a dome portion of the rock bit resulting in fluid, as it leaves the exit end of the nozzle, continues to diffuse outboard creating a larger surface area to entrain fluid. The diffused spray of fluid at a lesser velocity will better clean the rotary cones by moving the fluid closer to the cones without erosive damage to the cones or loss of cutter inserts or milled teeth. The diffused spray will additionally cover a larger area of a borehole bottom resulting in better bottom hole cleaning.

Abstract: A nozzle sleeve for the retention of replaceable fluid nozzles for rock bits is disclosed. The sleeve is secured within the body of the rock bit. A first upstream end of the sleeve communicates with a fluid plenum formed by the bit body. A second downstream end of this sleeve is adapted to receive the fluid nozzles. An elliptical fluid entrance is formed at the first upstream end of the nozzle sleeve. The elliptical fluid inlet formed by the sleeve serves to increase the flow of fluid to the nozzles, reduce turbulence of the fluid and substantially reduce the erosive effects associated with high fluid velocities and turbulent flow.

Abstract: A method to apply a high performance overlay to a metal substrate of a rock bit to render the substrate surfaces of the rock bit more resistant to erosion, corrosion and substrate cracking while performing in an earthen formation is described. The method comprises the steps of bombarding the surfaces with a thermal spray of entrained fine particles of a cermet based composition at a velocity in excess of 3,000 ft/per sec. The resultant coating of the cermet based composition has a tensile bond strength in excess of 20,000 psi that results in an increase of the strain to fracture of the rock bit surface. The hard overlay has a resistance to severe service environments of high strain and shock tolerance as well as a higher load carrying capacity.

Abstract: A method of manufacturing a rock bit leg from a rough bit leg forging is disclosed whereby multiple machining operations are performed by a six-axis CNC machining center. Three dimensional datum surfaces are initially formed on a rough leg forging. The rough leg forging is then mounted in a holding fixture. The fixture, including the leg forging, is secured to the six-axis CNC machining center. A three dimensional datum reference from the leg forging is set into the NC function of the six-axis machining center.The rough leg forging includes a pair of extended flanges coincident with the 120.degree. leg surfaces. The leg flanges mount to complimentary surfaces formed on the leg holding fixture, thus securing the leg within the fixture without interference of any of the machining processes.The CNC machining center performs a majority of the material removal operations to prepare the leg for subsequent assembly through manipulation of the six interactive axes of the CNC machining center.

Abstract: A composite mini-extended nozzle is disclosed that is designed to both resist erosion and be strong enough to withstand the shock of a downhole drilling environment. In addition, means are provided to shroud at least a portion of the extended nozzle to further protect a portion of the nozzle nearest the exit plane from downhole obstructions. A combination of materials used to form the nozzle may include a matrix of tungsten carbides with suitable binder joined to an outer metal jacket nozzle body. A third ceramic matrix material may be utilized to line or partially line an interior passage formed by the mini-extended nozzle and a reduced in diameter portion of the nozzle design may include a built-in fracture plane in the unlikely event the end of the nozzle hits an obstruction. The extended portion of the nozzle will shear off along this fracture plane thereby preventing a nozzle washout that likely would result in a trip out of the hole to repair the resultant damage to the rock bit.

Abstract: A self-contained, telescoping liner hanger setting tool is adapted to set a hanger and attached liner within a wellbore; release the liner hanger by unthreading a running nut securing the tool to the hanger and rotating the liner, after the tool is released from the hanger, during a cementing process, the liner is rotated through a clutch means adjacent the lower end of the tool and the upper end of the hanger, the liner hanger setting tool being fully retrievable from the borehole after the cementing process is ended.

Abstract: There is provided a method for making diamond and CBN composites, under HP/HT conditions, which comprises bonding a thin refractory material layer on the planar face of the tungsten carbide substrate proximate the diamond or CBN layer. There is also provided a small quantity of fine particles of yet another refractory material admixed in the diamond or CBN layer. The cooperation of these two systems greatly aid in regulating the flow of molten carbide bond metal from the substrate into the diamond or CBN layer, which minimizes abnormal grain growth and bond metal depletion at the diamond/substrate interface.

Abstract: A starter mill adapted for use with a whipstock to mill a window through the casing of a well for deviating the direction of drilling. The starter mill includes a bearing nose which is utilized to indicate completion of the milling process. As the mill nears completion of the milling process, the bearing nose will become wedged between the whipstock face and the casing preventing further downhole movement. The bearing nose will engage whipstock and casing, allowing the work string to continue to rotate although the decreased torque resulting from the absence of milling provides a clear signal that the milling operation is complete. The cutters of the mill are spaced a predetermined distance from the bearing nose to ensure completion of the casing window.

Abstract: A method to back ream a borehole drilled with a roller cone drill bit is taught. Protruding hard metal cutting inserts are affixed on the upper outside diameter tapered shoulder of each of the bit legs. If the borehole closes to a smaller diameter than the bit gage diameter or loose rock rubble packs around the upper portion of the bit, the protruding cutting inserts fixed on the upper leg tapered shoulder portion back ream the borehole by lifting and rotating the bit.

Abstract: A roller cone drill bit is disclosed that leaves uncut a substantial formation core having a diameter from 10% to 25% of the bit gage diameter. The bit is designed to have normal size bearings, cone shell thickness and cutter protrusion to allow the use of standard drilling weights and RPM, thereby achieving a significant increase in drilling rate. When drilling abrasive formations, ultra hard cutting teeth are used in the cone apex to maintain the core diameter.

Abstract: A hydraulic control sub assembly for actuating hydraulically operated downhole remedial tools, such as section mills or underreamers, is disclosed. The control sub features a drop ball mechanism to terminate the flow of drilling fluid to the hydraulic tool thereby inactivating the tool. The control sub also has a hydraulic rupture disc that permits drilling fluid circulation when tripping the drill pipe. The control sub further contains upwardly directed jet nozzles to enhance fluid flow in the well bore to help clear away debris. A float valve is also incorporated in the control sub to ensure there is no fluid under high pressure trapped in the hydraulic tool that may jam the tool.

Abstract: A polycrystalline diamond compact (PDC) drag bit cutter is disclosed that provides more clearance between the cutter's drilling edge and the drag bit body mounting blade. This allows for more efficient hydraulic cooling and cleaning of the cutters, thereby achieving faster drilling rates. A cylindrical carbide cutter base end having an off-set asymmetric diamond cutting end provides for less interference of the bit head surfaces and the rock formation being drilled, thereby reducing detrimental heat and also allowing a greater depth of penetration of the cutter.

Abstract: A unitized polycrystalline composite diamond stud type drag bit cutter having no high temperature braze of a PDC wafer to a carbide stud is disclosed. The diamond cutting surface may be planar, convex, curved or a truncated cone. The unitized construction of the cutter eliminates the problems associated with the high temperature brazing of a PDC wafer to a carbide stud.

Abstract: A drag bit for soft, sticky formations is disclosed with a new fluid dynamics control mechanism that minimizes "bit-balling". Multiple blades carrying PDC cutters have tapered back sides to achieve greater velocity through the fluid channels. Multiple jet nozzles in each fluid channel create interacting vortices that produce extremely turbulent flow thereby minimizing the coagulation and deposition of the hydrated clay cuttings on the bit cutting surfaces.

Abstract: An elastomeric o-ring rock bit seal is disclosed with two or more integrally bonded elastomers or phenolic type materials joined together to form the seal. The dynamic sealing face adjacent the journal bearing is fabricated from an elastomer/phenolic engineered specifically for wear resistance. The bulk of the seal adjacent the static seal retention cavity typically formed in the rotary cone is molded from an elastomer engineered specifically for precise control of the seal contact force adjacent the dynamic seal face when the seal is compressed against the dynamic face by the seal retention cavity in the cone.

Abstract: Sealed bearing roller cone rock bits are prone to seal wear and failure due to the encroachment of abrasive drill cuttings into the seal gland. A hard metal cuttings diverter pad angularly positioned across the bit leg backface, adjacent the trailing edge of the leg shirttail edge, wipes the accumulated drill cuttings from the rotating cone backface. A circumferential groove, formed in the bit leg backface, promotes a relatively high volume flow of drilling fluid at the seal gland entrance to flush away the abrasive cutting particles not diverted by the hard metal diverter pad.

Abstract: A drag bit mold fabricated from high temperature resisting material is machined to accept cylindrically shaped polycrystalline diamond cutters (PCD) having tungsten carbide bodies. Each of the multiple PCD matrix pockets in the mold is formed by two independent non-parallel end mill passes. The first end mill cut defines the PCD cutter position in the cutting face of the matrix diamond drag bit. The second end mill cut superimposed over the first end mill pocket creates a surrounding pocket which fills with powder metallurgy matrix material to provide support for the cylindrical cutter. The second end mill is only slightly larger than the first end mill to minimize the size of the insert securing fillet subsequently formed thus assuring that the fillet will not interfere with the depth of penetration of each of the PCD cutters.