Abstract: Steel bit bodies are manufactured with polystyrene patterns in a lost foam casting process. The patterns are machined in complex shapes that cannot be extractable from reusable, two-piece pattern molds. The patterns are machined in a basic, programmed, five-axis machining process to form multiple copies of a complex pattern body. The process is modified to produce multiple copies of a modified design. Multiple bit patterns of variable forms are produced without an intermediate, reusable pattern mold that would require multiple mold pieces, thus eliminating the time and expense in variation of the bit design. The pattern is machined in a single chucking operation in a machine tool adapted for machining plastics in a three-dimensional global process. The plastic composition and density permit it to be machined into a pattern having relatively small, unsupported structural projections and smooth surface features.

Abstract: Steel bit bodies are manufactured with polystyrene patterns in a lost foam casting process. The patterns are machined in complex shapes that cannot be extracted from reusable, two-piece pattern molds. The patterns are machined in a basic, programmed, five-axis machining process to form multiple copies of a complex pattern body. The process is modified to produce multiple copies of a modified design. Multiple bit patterns of variable forms are produced without an intermediate, reusable pattern mold that requires multiple mold pieces, thus eliminating the time and expense in variation of the bit design. The pattern is machined in a single chucking operation in a machine tool adapted for machining plastics in a three-dimensional global process. The plastic composition and density permit it to be machined into a pattern having relatively small, unsupported structural projections and smooth surface features.

Abstract: A fixed cutting element drill bit is provided with primary cutting elements which are spaced radially from each other across the face of the bit. During drilling, the gap between the cutting elements causes a ridge to be formed in the bottom of the well and the apex of the ridge is removed before reaching the face of the bit. In one form of the invention, the apex is broken off by utilization of the sides of the supports for the primary cutting elements.

Abstract: A fixed cutting element drill bit is provided with primary cutting elements which are spaced radially from each other across the face of the bit. During drilling, the gap between the cutting elements causes a ridge to be formed in the bottom of the well and the apex of the ridge is removed before reaching the face of the bit. In one form of the invention, the apex is broken off by utilization of the sides of the supports for the primary cutting elements.