Abstract: A PDC bit includes a plurality of blades. A blade includes a primary cutter row and a secondary cutter row. Primary PDC cutters on the primary cutter row are set in accordance with a single set methodology. Backup PDC cutters on the secondary cutter row are set in accordance with a methodology wherein a radial position of each backup PDC cutter in the secondary cutter row is offset from a radial position of each primary PDC cutter in the primary cutter row. The blade further includes a tertiary cutter row. Additional backup PDC cutters on the tertiary cutter row are set in accordance with a methodology wherein a radial position of each additional backup PDC cutter in the tertiary cutter row is offset from a radial position of each primary PDC cutter in the primary cutter row. The backup cutter setting methodology is effectively radially positions the included backup PDC cutters (in the secondary cutter row and/or tertiary cutter row) between primary PDC cutters in the primary cutter row.

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

Abstract: A drag type casing mill/drill bit for down hole milling of a casing window and lateral drilling of a bore hole in an earth formation comprises a bit body adapted to be rotated in a defined direction. The bit body includes an operating end face having a plurality of radially extending blades formed as a part of the operating end face of the bit body. A plurality of primary cutting elements are individually mounted in pockets in one of the plurality of blades. In addition, a plurality of secondary ridge structures are mounted to each of the plurality of blades interspersed with the plurality of primary cutting elements in a pattern such that as the bit body rotates the secondary ridge structures contact the casing or the earth formation thereby protecting the primary cutting elements and allowing continuous substantially smooth casing milling and earth formation drilling.

Abstract: A drill bit is assembled to the makeup end of a drill string by means of a breakable washer comprising a ring-shaped body having an inner diameter and an outer diameter. A radially extending first surface of the ring-shaped body is planar and substantially perpendicular to a centerline axis through the body. A second radially extending surface has an angle with reference to the first surface that results in a radially diverging configuration.

Abstract: A seal assembly for a shaft supporting a rotary element comprises a sealing ring having an inner radial surface in contact with a seal surface of the shaft. The sealing ring comprising a disc shaped integral radial lip normal to the inner radial surface. A disc shaped seal shield is assembled in sealing contact with a first surface of the integral disc shaped radial lip and also in sealing contact with a first radial surface of an annular seal groove. An energizer positioned in the annular seal groove is in contact with the bottom surface of the groove and a second radial surface of the groove. The energizer exerts a radial force on the outer radial surface of the sealing ring and a lateral force on the integral radial lip of the sealing ring.

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

Abstract: A cutting element for an earth boring bit comprises a cutting compact of a superabrasive material layer bonded to a supporting substrate. The superabrasive material layer has a pattern of radially extending ribs, the ribs extending from the peripheral surface of the layer, and a second pattern of circular ribs radially spaced from the peripheral surface and intersecting the first pattern of radially extending ribs. The supporting substrate comprises a first pattern of radially extending grooves for mating with the first pattern of radially extending ribs. In addition, the supporting substrate comprises a second pattern of circular grooves for mating with the first pattern of circular ribs. The interface between the substrate and the superabrasive material has a dome-shaped configuration.

Abstract: A drag type casing mill/drill bit for down hole milling of a casing window and lateral drilling of a bore hole in an earth formation comprises a bit body adapted to be rotated in a defined direction. The bit body includes an operating end face having a plurality of radially extending blades formed as a part of the operating end face of the bit body. A plurality of primary cutting elements are individually mounted in pockets in one of the plurality of blades. In addition, a plurality of secondary ridge structures are mounted to each of the plurality of blades interspersed with the plurality of primary cutting elements in a pattern such that as the bit body rotates the secondary ridge structures contact the casing or the earth formation thereby protecting the primary cutting elements and allowing continuous substantially smooth casing milling and earth formation drilling.

Abstract: A rotary cone drill bit includes a drill bit body having two or more support spindles extending inward and downward toward a vertical axis of the drill bit body. Each support spindle of the drill bit includes a base pin and further includes a pilot pin extending from the base pin along a longitudinal axis of the support spindle. A conical-shaped thrust face forms the transition from the base pin to the pilot pin. A cutting cone is rotatably mounted on each support spindle and includes a conical internal surface to run in contact with the conical thrust face of the support spindle. Rotation of the cutting cone carries lubricant from the non-load side of the spindle to the contact surfaces on the load side of the spindle.