Abstract: A cutting element for use on a rotary-type earth boring drill bit for drilling subterranean formations including a segment and a support member. The support member is preferably fabricated from a tough and ductile material, such as iron, an iron-based alloy, nickel, a nickel-based alloy, copper, a copper-based alloy, titanium, a titanium-based alloy, zirconium, a zirconium-based alloy, silver, or a silver-based alloy. A bit attachment portion of the support member is securable to a bit body. A segment-receiving portion of the support member is disposable within a recess formed in the segment to secure the segment to the bit body and support the segment during use of the drill bit. Preferably, the segment is fabricated from a hard continuous phase material that is impregnated with a particulate abrasive material, such as natural diamond, synthetic diamond, or cubic boron nitride.

Abstract: A torque limiting device that allows a drill string to rotate relative to the cutting structure of the bit when a predetermined torque is applied between the cutting structure of the drill bit and the drill string. The torque limiting device utilizes a retaining member which restricts rotational movement of a first component of the torque limiting device relative to a second component. When a sufficient torque load is placed on the cutting structure of the drill bit, the retaining member allows rotational movement of the first component relative to the second component and allows the drill string to continue to rotate relative to the cutting structure of the bit until the torque is sufficiently reduced. The torque limiting device may be an integral part of a drill bit, may be a separate device attached between the drill string and the drill bit or between the drill string and a downhole motor, or may be part of a near-bit sub or incorporated in a downhole motor.

Abstract: A torque limiting device that allows a drill string to rotate relative to the cutting structure of the bit when a predetermined torque is applied between the cutting structure of the drill bit and the drill string. The torque limiting device utilizes a retaining member which restricts rotational movement of a first component of the torque limiting device relative to a second component. When a sufficient torque load is placed on the cutting structure of the drill bit, the retaining member allows rotational movement of the first component relative to the second component and allows the drill string to continue to rotate relative to the cutting structure of the bit until the torque is sufficiently reduced. The torque limiting device may be an integral part of a drill bit, may be a separate device attached between the drill string and the drill bit or between the drill string and a downhole motor, or may be part of a near-bit sub or incorporated in a downhole motor.

Abstract: A cutting element for use on a rotary-type earth boring drill bit for drilling subterranean formations including a segment and a support member. The support member is preferably fabricated from a tough and ductile material, such as iron, an iron-based alloy, nickel, a nickel-based alloy, copper, a copper-based alloy, titanium, a titanium-based alloy, zirconium, a zirconium-based alloy, silver, or a silver-based alloy. A bit attachment portion of the support member is securable to a bit body. A segment-receiving portion of the support member is disposable within a recess formed in the segment to secure the segment to the bit body and support the segment during use of the drill bit. Preferably, the segment is fabricated from a hard continuous phase material that is impregnated with a particulate abrasive material, such as natural diamond, synthetic diamond, or cubic boron nitride.

Abstract: A drill bit and method of drilling a subterranean formation are disclosed in which the drill bit is configured with a non-axial gage portion of a bit body. The non-axial gage portion of the bit body presents a peripheral profile which is not parallel to the centerline of the bit body to provide a contact area for engagement of the sidewall of the borehole by at least one cutting element carried by the non-axial gage portion to enlarge the borehole from a first diameter cut by cutting elements on the bit face. The configuration of the drill bit lessens loading on the cutting elements of the drill bit, facilitates maneuverability of the drill bit downhole and enhances steerability of the drill bit.

Abstract: A cutting element for use in drilling subterranean formations. The cutting element includes a superabrasive table mounted to a supporting substrate. The superabrasive table includes a two-dimensional cutting face having a cutting edge along at least a portion of its periphery, and a first surface extending forwardly and inwardly from a location radially interior of the cutting edge at a first angle of orientation with respect to the longitudinal axis of the cutting element. The cutting face also includes at least a second surface located between the first surface and the cutting edge and oriented at a different, greater angle to the longitudinal axis than the angle of orientation of the first surface.

Abstract: A drill bit and method of drilling employing a gage definition region on the bit to relatively gradually and incrementally increase the diameter of the borehole being drilled from a diameter that is cut by fixed face cutters or rolling cone cutters on the bit body to a larger diameter. Preferably, the diameter of the gage definition region defined by cutting structures thereon varies along a longitudinal length of the bit, being smallest nearest the leading end of the bit. In a preferred embodiment, the gage definition region includes a plurality of helically arranged cutting elements disposed around the perimeter of the gage definition region. Such a configuration of cutting elements helps to reduce the loading on, and wear of, each individual cutting element. Thus the effective life of the bit is extended by enhancing its ability to drill the borehole to the gage diameter over a longer interval than may be achieved with conventional bit designs.

Abstract: A polycrystalline diamond layer attached to a cemented metal carbide structure used as a cutter in a drill bit wherein the cutter has improved toughness or fracture resistance during use through the inclusion of boron, beryllium or the like therein.

Abstract: A diamond cutting element for use on an earth boring drill bit, such as a rotary drag bit. The cutting element is predominately comprised of a diamond cutting structure attached to either a reduced-volume substrate or directly to a bit body, optionally using a carrier structure mounted to the bit body. With such a configuration, stress between dissimilar materials, such as the substrate and the cutting structure, is reduced or entirely eliminated. Moreover, only the diamond cutting structure contacts the formation during drilling, resulting in lower friction, lower temperatures and lower wear rates of the cutting elements. The diamond cutting structure may also be polished and include one or more internal passageways that extend into the diamond through which fluids may be passed to transfer heat from the cutting element during drilling.

Abstract: A drill bit employing selective placement of cutting elements engineered to accommodate differing loads such as are experienced at different locations on the bit crown. A method of bit design and cutting element design to achieve optimal placement for maximum ROP and bit life of particularly suitable cutting elements for a given bit profile and design, as well as anticipated formation characteristics and other downhole parameters.

Abstract: A cutting element and drill bits so equipped particularly suited for drilling subterranean formations exhibiting a superabrasive cutting face with at least a portion of extremely low surface roughness, by way of example on the order of a polished, mirror-like finish. The cutting face includes a peripheral cutting edge adjacent the low surface roughness portion of the cutting face for engaging a subterranean formation, the cutting edge being of sharp configuration and essentially defining a line of contact with the formation lying between the cutting face and a side surface of the cutting element extending rearwardly therefrom. In certain formations, particularly soft, plastic formations, the drill bits equipped with the inventive cutting element may be employed as a system and method with drilling fluids modified to maintain the integrity of formation cuttings by stabilizing and locking in reactive clays present in the rock to inhibit bit balling and facilitate hydraulic cuttings removal from the bit face.

Abstract: A cutting element for use in drilling subterranean formations. The cutting element includes a superabrasive table between about 0.070 inch and 0.150 inch thickness, mounted to a supporting substrate. The superabrasive table includes a two-dimensional cutting face having a cutting edge along at least a portion of its periphery, and a rake land extending forwardly and inwardly from the cutting edge at an angle of between about 10.degree. and 80.degree. to the longitudinal axis of the cutting element for a width, measured along the surface of the rake land, of not less than about 0.050 inch. The interface between the superabrasive volume and the substrate, taken to the rear of the cutting edge, is located no less than about 0.015 inch to the rear of the cutting edge.

Abstract: A drill bit employing selective placement of cutting elements engineered to accommodate differing loads such as are experienced at different locations on the bit crown. A method of bit design and cutting element design to achieve optimal placement for maximum ROP and bit life of particularly suitable cutting elements for a given bit profile and design, as well as anticipated formation characteristics and other downhole parameters.

Abstract: A torque limiting device that allows a drill string to rotate relative to the cutting structure of the bit when a predetermined torque is applied between the cutting structure of the drill bit and the drill string. The torque limiting device utilizes a retaining member which restricts rotational movement of a first component of the torque limiting device relative to a second component. When a sufficient torque load is placed on the cutting structure of the drill bit, the retaining member allows rotational movement of the first component relative to the second component and allows the drill string to continue to rotate relative to the cutting structure of the bit until the torque is sufficiently reduced. The torque limiting device may be an integral part of a drill bit, maybe a separate device attached between the drill string and the drill bit or between the drill string and a downhole motor, or may be part of a near-bit sub or incorporated in a downhole motor.

Abstract: A diamond cutting element for use on an earth boring drill bit, such as a rotary drag bit. The cutting element is predominately comprised of a diamond cutting structure attached to either a reduced-volume substrate or directly to a bit body, optionally using a carrier structure mounted to the bit body. With such a configuration, stress between dissimilar materials, such as the substrate and the cutting structure, is reduced or entirely eliminated. Moreover, only the diamond cutting structure contacts the formation during drilling, resulting in lower friction, lower temperatures and lower wear rates of the cutting elements. The diamond cutting structure may also be polished and include one or more internal passageways that extend into the diamond through which fluids may be passed to transfer heat from the cutting element during drilling.

Abstract: Mounting apparatus is described for locking an insertable stud cutter or slug cutter or fluid nozzle into a socket on a rotatable earth boring drill bit. The cutter may be readily removed and replaced without damaging either the cutter, nozzle or bit. Apparatus are shown for permitting or, alternatively, preventing rotation of the cutter or nozzle in its socket. The mounting apparatus is particularly applicable to cutters having a cutting disk of polycrystalline diamond or other superabrasive material mounted on a carbide supporting body, or carbide body nozzles or nozzles having a bore lined with such a material.

Abstract: A method for making an earth boring drill bit which includes an outer shell having an external surface adapted to carry cutting elements and a unitary shank and bit core which is fitted into the outer shell. The shell and bit core are threadably engaged with one another or are interferingly engaged. The shell and bit core may be welded, secured with brazing alloys or with high temperature adhesives. In one embodiment, a ridge formed on the shank is received in a groove formed on an interior surface of the shell to prevent relative rotational movement of the shank and shell during drilling. In another embodiment, the shell is formed using matrix infiltration techniques. After the shell is formed, it is heated to braze cutters thereto. While still hot from the brazing process, the shell and shank are fitted together. After cooling the shell contracts to form heat shrink connection between the shell and the shank.

Abstract: A polycrystalline diamond layer attached to a cemented metal carbide structure used as a cutter wherein the cutter has improved toughness or fracture resistance during use through the inclusion of boron, beryllium or the like therein.

Abstract: A drill bit employing selective placement of cutting elements engineered to accommodate differing loads such as are experienced at different locations on the bit crown. A method of bit design and cutting element design to achieve optimal placement for maximum ROP and bit life of particularly suitable cutting elements for a given bit profile and design, as well as anticipated formation characteristics and other downhole parameters.

Abstract: A drill bit, process of drilling, and method of manufacturing the same are provided wherein the drill bit has a bit body defining a radially extending waist and a plurality of cutting elements proximate the waist. The waist has an outer diameter less than an outer diameter defined by a plurality of outermost cutting elements. The difference in outer diameters between the waist and the outermost cutting elements is determined by the thickness of filter cake that forms on the wall of a wellbore, such that the waist of the bit does not contact the filter cake during the drilling process.