Abstract: An expandable tool includes a body and a recess extending at least partially through the body from an outer radial surface of the body. A spline insert may be at least partially positioned in the recess and coupled to the body. The spline insert may include a single spline or multiple splines. A cutter block or other expandable member may be at least partially positioned in the recess. The cutter block or other expandable member may include a spline on a side surface thereof, which spline may be engaged with the one or more splines of the spline insert. Engagement between one or more splines of the spline insert and spline of the cutter block or other expandable member may allow the expandable member to move radially outward from a retracted position to an expanded position, and vice versa.

Abstract: An expandable tool includes a body and a recess extending at least partially through the body from an outer radial surface of the body. A spline insert may be at least partially positioned in the recess and coupled to the body. The spline insert may include a single spline or multiple splines. A cutter block or other expandable member may be at least partially positioned in the recess. The cutter block or other expandable member may include a spline on a side surface thereof, which spline may be engaged with the one or more splines of the spline insert. Engagement between one or more splines of the spline insert and spline of the cutter block or other expandable member may allow the expandable member to move radially outward from a retracted position to an expanded position, and vice versa.

Abstract: An expandable tool includes a body and a recess extending at least partially through the body from an outer radial surface of the body. A spline insert may be at least partially positioned in the recess and coupled to the body. The spline insert may include a single spline or multiple splines. A cutter block or other expandable member may be at least partially positioned in the recess. The cutter block or other expandable member may include a spline on a side surface thereof, which spline may be engaged with the one or more splines of the spline insert. Engagement between one or more splines of the spline insert and spline of the cutter block or other expandable member may allow the expandable member to move radially outward from a retracted position to an expanded position, and vice versa.

Abstract: An expandable tool includes a body and a recess extending at least partially through the body from an outer radial surface of the body. A spline insert may be at least partially positioned in the recess and coupled to the body. The spline insert may include a single spline or multiple splines. A cutter block or other expandable member may be at least partially positioned in the recess. The cutter block or other expandable member may include a spline on a side surface thereof, which spline may be engaged with the one or more splines of the spline insert. Engagement between one or more splines of the spline insert and spline of the cutter block or other expandable member may allow the expandable member to move radially outward from a retracted position to an expanded position, and vice versa.

Abstract: A downhole tool has a body with a bore formed at least partially therethrough. A cutter block may be coupled to the body and move radially outward from the body in response to an increased pressure in the bore. The cutter block may include an outer surface that transitions from a first portion to a second portion, with the first portion being downhole of the second portion. A radius of curvature between the first and second portions may be less than about 7 cm. The second portion or a line tangential thereto may be oriented at an angle from about 60° to about 120° with respect to a central longitudinal axis of the body. A plurality of cutting elements may be disposed on the outer surface of the cutter block. At least one of the cutting elements may be disposed at least partially on the first or second portion of the outer surface.

Abstract: Reamer elements for use with roller reamers and other types of reamer apparatuses, methods for forming such reamer elements, and methods for performing drilling operations using such reamer elements are disclosed. The reamer element includes a body formed from a matrix of tungsten carbide and at least one binding metal, and can include a tube disposed therethrough. In use, the body resists compressive forces, while the tube resists tensile forces, thereby preventing deformation of the reamer element. The matrix material of the body provides increased wear resistance, decreased magnetic interference, decreased yield, and increased weight on a drill bit when compared to conventional steel components.

Abstract: A graphite core mold having its own cavity is pressed into a cavity of a graphite shell mold. The core cavity is filled with tungsten carbide, mixed with a nickel alloy, heated and then cooled to thereby provide a carbide matrix body. After milling the carbide matrix body to thereby provide a carbide bit body, the intact shell mold is removed and then used again.