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: 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 drill bit for drilling subterranean formations includes a device to provide a "universal" effect between the shank and crown for self alignment of the crown with the bore hole in the formation. The bit is suitable for downhole assemblies configured for straight drilling, directional drilling and navigational drilling. The device can be incorporated into both drag bits and roller-type "rock" bits. Preferred embodiments include a flexible sub connecting the crown to the shank portion and having reduced stiffness relative to the drill string. Alternatively, a spherical universal joint or trunnion type universal is used. Replaceable lugs increase durability and reliability of the universal. The device equalizes the loads on cutters while reducing wear, average loads, and impact loads on cutters. Bore hole diameter and chatter of the bit in the bore hole are reduced, promoting maximum efficiency and rate of penetration as wobble and precession are minimized.

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 drilling apparatus having cuttings removal structure to reduce balling thereof comprising an apparatus body having a connection thereon, and structure for contacting cut potions of the earth formation. The contacting structure may include chip breakers, flexible cables, rotating nozzle assemblies, rotating turbine wheel assemblies, rotating vane assemblies, flails or combinations of these. The apparatus may include elastomeric portions and/or movable potions. The drilling apparatus may comprise a drill bit, drilling stabilizer, drill collar, reamer, downhole motor, etc.

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 for drilling subterranean formations includes a device to provide a "universal" effect between the shank and crown for self alignment of the crown with the bore hole in the formation. The bit is suitable for down-hole assemblies configured for straight drilling, directional drilling and navigational drilling. The device can be incorporated into both drag bits and roller-type "rock" bits. Preferred embodiments include a flexible sub connecting the crown to the shank portion and having reduced stiffness relative to the drill string. Alternatively, a spherical universal joint or trunnion type universal is used. Replaceable lugs increase durability and reliability of the universal. The device equalizes the loads on cutters while reducing wear, average loads, and impact loads on cutters. Bore hole diameter and chatter of the bit in the bore hole are reduced, promoting maximum efficiency and rate of penetration as wobble and precession are minimized.

Abstract: A cutting element for a rotary drill bit for subterranean drilling, including a substantially planar table of superhard material having a cutting face and a cutting edge. The table may be reinforced against bending with one or more strut portions extending from the rear of the table to the rear of the substrate and at least partially across the cutting element. The strut portions may be integral with the diamond table, or separately fabricated and of another material. The strut portions, in addition to or in lieu of providing stiffness to the superhard table, may also serve to enhance heat transfer away from the cutting face and cutting edge of the superhard table. The structure supporting the cutting element on the drill bit and the body of the drill bit itself may be additionally configured to include structures to facilitate heat transfer away from the superhard table.

Abstract: A drill bit for boring an earth formation is designed for rotation in a given direction. The bit body includes an operating face with at least one cutting element formed thereon. A cutting surface formed on the cutting element faces in a forward direction with respect to the direction of rotation. A cutting edge is formed on the cutting surface and is embedded in the earth formation during boring so that the formation is received against a portion of the cutting surface. The cutting element creates successive formation chips during boring which grow in length during bit rotation. A chip breaker formed adjacent the cutting surface imparts a strain to the chip by bending and/or twisting the chip and thereby increases the likelihood that it will break off. In one aspect, fluid flows in a fluid course formed in front of the cutting element during boring. Twisting increases the surface area of the chip presented to fluid in the fluid course which further increases the likelihood that the chip will break.

Abstract: A rotary bit for drilling subterranean formations. The bit includes a separately-fabricated bit body and cutter support structures, the latter of which may be designed as blades, ribs, pads or otherwise, depending upon the bit style. The body and one or more cutter support structures are assembled and secured together after fabrication. Separate fabrication of the cutter support structures permits more precise cutter positioning, as well as orientation, and promotes the use of stronger and more diverse cutter affixation means. The cutter support structures may be adjustably radially movable with respect to the bit body, so as to provide the ability to fabricate bits of various gage sizes within a range using a single bit body and single size of cutter support structure.

Abstract: A full cutting element including a substantially cylindrical backing and cutter mounted thereon is cut generally along the length thereof to produce a pair of semicylindrical partial cutting elements. In the case of an unused cutting element, each partial cutting clement is mounted on a different semicylindrical tungsten carbide base to produce a substantially cylindrical unit which is mounted on a bit using a low temperature braze. In the case of a used full cutting element, the cutting clement is cut to separate the worn portion from the remainder of the bit and only the unused portion is used to form a cylindrical unit with a corresponding semicylindrical tungsten carbide base. In another aspect, a partial cutting element is received in a pocket formed on a bit body. The pocket includes a pair of opposed side surfaces which substantially flushly abut the curved surfaces of the backing on the partial cutter.

Abstract: A drill bit for drilling subterranean formations includes a device to provide a "universal" effect between the shank and crown for self alignment of the crown with the bore hole in the formation. The bit is suitable for downhole assemblies configured for straight drilling, directional drilling and navigational drilling. The device can be incorporated into both drag bits and roller-type "rock" bits. Preferred embodiments include a flexible sub connecting the crown to the shank portion and having reduced stiffness relative to the drill string. Alternatively a spherical universal joint or trunnion type universal is used. Replaceable lugs increase durability and reliability of the universal. The device equalizes the loads on cutters while reducing wear, average loads, and impact loads on cutters. Bore hole diameter and chatter of the bit in the bore hole are reduced, promoting maximum efficiency and rate of penetration as wobble and precession are minimized.

Abstract: A rotary drag bit for drilling hard rock formations with substantially planar PDC cutting elements having diamond tables backed by substrates which flare or taper laterally outwardly and rearwardly of the cutting edge of the diamond table. A cutting structure defining a "lipped" cutting edge is also disclosed.

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 cutting element having a substantially planar table of superhard material mounted on a substrate or backing. The superhard material table, the substrate, or an insert placed between those two components provides additional stiffness to the cutting element and resistance to bending and impact loading experienced by the cutting element when drilling a formation. The additional stiffness reduces fracture of the table of superhard material and, if the reinforcing member or portion is formed of an abrasion and erosion resistant material, the cutting element will wear linearly at a reduced rate due to the enhanced volume of such material. The thicker or reinforced portion of the cutting element extends linearly, and if the cutting element is circular, extends diametrically. Cooperative arrangements of such cutting elements are also disclosed.

Abstract: An improved stud design for an earth boring drill bit is disclosed preferably using materials of different hardness and toughness layered to provide maximum resistance to surface abrasion coupled with excellent structural properties including high strength with maximum fracture toughness. The bit body is conventionally attached to a drill string, and has a crown and gage portion. The studs preferably include a core, made of steel or other material having high fracture toughness, covered at least in part with a hard, abrasion resistant material such as tungsten carbide. Each stud is secured to a socket in the bit body by means of brazing or other suitable means such as a press fit. The cutting element is brazed to a mounting face of the stud prior to affixation of the stud to the bit body and is preferably comprised of a polycrystalline diamond compact adhered to a backing layer of tungsten carbide.

Abstract: A drill bit, and a cutter for a drill bit, are provided, wherein the cutter will encounter the formation with cutting surfaces of differing rake angles to optimize cutting efficiency. In most circumstances, the cooperating cutters will have differing, positive, and negative or neutral rakes. Cutters of differing rakes may be cooperatively paired on a drill bit such that the portion of a formation which is affected by the action of one cutter may be similarly affected by the operation of the other cutter.

Abstract: A drill bit for use with earth drilling equipment, the drill bit having a body and movable cutting members or blades variably positionable between a first position in which the diameter defined by the cutting members is generally equal to or less than the diameter of the drill bit body and a second position in which the diameter defined by the cutting members is greater than the diameter of the drill bit body. The second, expanded position is assumed by the cutting members when they are in contact with the bottom of a hole and are thereby urged upwardly relative to the bit body. The first, retracted position is assumed by the cutting members when the drill bit is being tripped into or out of the hole and, because the cutting members are essentially retracted relative to the bit body, the drill bit does not become jammed downhole. A fixed-blade adaptation of the invention is also contemplated.

Abstract: An improved earth-boring bit the rolling cone variety and an insert for use therein is provided. A superabrasive element is coated with at least one layer of metallic material. The superabrasive element then is placed in a receptacle cavity in a pre-formed hard metal jacket. The superabrasive element then is brazed or infiltrated to the hard metal jacket. Metallurgical and mechanical bonds between the superabrasive element, the at least one layer of metallic material on superabrasive element, the braze or infiltrant binder material, and the fracture-tough material of the hard metal jacket retain the superabrasive element in the cavity of the hard metal jacket. Improved earth-boring bits according to this embodiment of the present invention provide abrasion-resistant earth-boring bits of the rolling cutter variety. Such improved bits, and the inserts therefore, are formed without resort to high-temperature, high-pressure processes.

Abstract: An improved earth-boring bit the rolling cone variety and an insert for use therein is provided. A superabrasive element is coated with at least one layer of metallic material. The superabrasive element then is placed in a receptacle cavity in a pre-formed hard metal jacket. The superabrasive element then is brazed or infiltrated to the hard metal jacket. Metallurgical and mechanical bonds between the superabrasive element, the at least one layer of metallic material on superabrasive element, the braze or infiltrant binder material, and the fracture-tough material of the hard metal jacket retain the superabrasive element in the cavity of the hard metal jacket. Improved earth-boring bits according to this embodiment of the present invention provide abrasion-resistant earth-boring bits of the rolling cutter variety. Such improved bits, and the inserts therefore, are formed without resort to high-temperature, high-pressure processes.