Abstract: A cutting element includes a sleeve, a rotatable cutting element, and at least one retaining ring. The sleeve has a first inner diameter and a second inner diameter, wherein the second inner diameter is larger than the first inner diameter and located at a lower axial position than the first inner diameter. The rotatable cutting element has an axis of rotation extending therethrough, a cutting face, a body extending axially downward from the cutting face, wherein the body has a shaft that is disposed within the sleeve, and a circumferential groove formed around an outer surface of the shaft. The at least one retaining ring is disposed in the circumferential groove and extends at least around the entire circumference of the shaft, wherein the at least one retaining ring protrudes from the circumferential groove, thereby retaining the rotatable cutting element within the sleeve.

Abstract: Cutter assemblies include an outer support and a cutting element disposed therein. The cutting element is immovably attached to the outer support element. Also disclosed is downhole tools incorporating such cutter assemblies and methods of making such downhole tools.

Abstract: A method of forming a cutting element may include placing a plurality of diamond particles adjacent to a substrate in a reaction cell and subjecting the plurality of diamond particles to high pressure high temperature conditions to form a polycrystalline diamond body. The polycrystalline diamond body may include a cutting face area to thickness ratio ranging from 60:16 to 500:5. The polycrystalline diamond body may have at least one dimension greater than 8 mm.

Abstract: A cutter assembly may include a sleeve having at least one passageway extending through the sleeve from a outer surface thereof into an inner surface thereof; at least one rotatable cutting element disposed in the sleeve, wherein the at least one rotatable cutting element has a circumferential groove formed in a side surface thereof, wherein when the inner rotatable cutting element is disposed in the sleeve, the circumferential groove is aligned with the passageway; and a retention element disposed in at least a portion of the passageway and the circumferential groove to retain the at least one rotatable cutting element in the sleeve, wherein the retention element has an axis that is parallel to a tangent of the rotatable cutting element side surface at least one point of contact with the rotatable cutting element.

Abstract: A cutting element is disclosed that includes a sleeve, a rotatable cutting element, and at least one retaining ring. The sleeve has a first inner diameter and a second inner diameter, wherein the second inner diameter is larger than the first inner diameter and located at a lower axial position than the first inner diameter. The rotatable cutting element has an axis of rotation extending therethrough, a cutting face, a body extending axially downward from the cutting face, wherein the body has a shaft that is disposed within the sleeve, and a circumferential groove formed around an outer surface of the shaft. The at least one retaining ring is disposed in the circumferential groove and extends at least around the entire circumference of the shaft, wherein the at least one retaining ring protrudes from the circumferential groove, thereby retaining the rotatable cutting element within the sleeve.

Abstract: A downhole cutting apparatus includes a tubular body and a cutter block extending radially therefrom. The cutter block includes at least one row of cutting elements. The row or cutting elements defines a cutting profile having a first underreaming cutting edge, a second underreaming cutting edge, and a first backreaming cutting edge between the first underreaming cutting edge and the second underreaming cutting edge.

Abstract: A downhole cutting apparatus includes a cutter block having a longitudinal blade. The longitudinal blade includes a first cutting edge adjacent a second cutting edge, and the first cutting edge and the second cutting edge are both either underreaming cutting edges, backreaming cutting edges, or a combination of underreaming and backreaming cutting edges.

Abstract: A cutting element assembly includes a sleeve, a lining extending a distance axially from an end of the sleeve, and an inner cutter. The inner cutter has a cutting end, wherein the cutting end extends a depth from a cutting face, a side surface, and a body, wherein the body is at least partially disposed within the sleeve, and wherein the side surface of the cutting end interfaces with an interfacing surface of the lining.

Abstract: A drill bit includes a bit body having a longitudinal bit axis extending there through, a plurality of journals extending from the bit body, each journal having a journal axis extending from a base of the journal through the length of the journal, a roller cone rotatably mounted to each of the journals, and at least one blade protruding from the bit body center and extending radially outward to less than an outer diameter of the drill bit.

Abstract: A cutting element may be formed by placing a plurality of diamond particles adjacent to a substrate in a reaction cell and subjecting the plurality of diamond particles to high pressure high temperature conditions to form a polycrystalline diamond body. The polycrystalline diamond body may have a cutting face area to thickness ratio ranging from 60:16 to 500:5 and at least one dimension greater than 8 mm.

Abstract: A downhole cutting tool may include a tool body, a plurality of blades extending azimuthally from the tool body comprising a cone region, a shoulder region, and a gage region, at least one cutting element disposed along the cone region and the shoulder region of the blade, and at least one gage cutting element disposed along the gage region of the blade wherein the at least one gage cutting element has a negative backrake ranging from greater than 70 to about 85 degrees.

Abstract: A cutting element assembly includes a sleeve, a lining extending a distance axially from an end of the sleeve, and an inner cutter. The inner cutter has a cutting end, wherein the cutting end extends a depth from a cutting face, a side surface, and a body, wherein the body is at least partially disposed within the sleeve, and wherein the side surface of the cutting end interfaces with an interfacing surface of the lining.

Abstract: A cutting tool is disclosed that includes a tool body, a plurality of cutting element support structures extending from the tool body, at least one slot formed in at least one of the cutting element support structures, a cutting element having a diamond shearing element with a plurality of surfaces, and at least one mechanical retention mechanism adjacent to the cutting element. Each cutting element support structure has a leading face, a top side, and a trailing face, and the slot has two side surfaces, each side surface terminating at the leading face and top side of the cutting element support structure. Each surface of the cutting element has two dimensional values, wherein the cutting element is positioned in the at least one slot such that a plane in which the shortest dimensional value lies intersects the slot side surfaces.

Abstract: A method for making a diamond compact includes pre-heating a diamond body which includes a carbonate catalyst to convert at least a portion of the carbonate catalyst into an oxide, assembling the diamond body and a substrate, providing a braze material between the diamond body and the substrate to form a diamond compact, heating the braze material to melt the braze material and form a braze joint between the diamond body and the substrate, and cooling the braze material after increasing the pressure. A bit having a diamond compact including a carbonate catalyst and a metal oxide mounted thereon.

Abstract: Polycrystalline diamond constructions comprises a diamond body attached to a metallic substrate, and having an engineered metal content. The body comprises bonded together diamond crystals with a metal material disposed interstitially between the crystals. A body working surface has metal content of 2 to 8 percent that increases moving away therefrom. A transition region between the body and substrate includes metal rich and metal depleted regions having controlled metal content that provides improved thermal expansion matching/reduced residual stress. A point in the body adjacent the metal rich zone has a metal content that is at least about 3 percent by weight greater than that at a body/substrate interface. The metal depleted zone metal content increases gradually moving from the body, and has a thickness greater than 1.25 mm. Metal depleted zone metal content changes less about 4 percent per millimeter moving along the substrate.

Abstract: Methods for joining an ultra-hard body, such as a thermally stable polycrystalline diamond (TSP) body, to a substrate and mitigating the formation of high stress concentration regions between the ultra-hard body and the substrate. One method includes covering at least a portion of the ultra-hard body with an intermediate layer, placing the ultra-hard body and the intermediate layer in a mold, filling a remaining portion of mold with a substrate material including a matrix material and a binder material such that the intermediate layer is disposed between the ultra-hard body and the substrate material, and heating the mold to an infiltration temperature configured to melt the binder material and form the substrate.

Abstract: A cutter assembly may include a sleeve; and at least one cutting element having a lower spindle portion retained in the sleeve and a portion of the cutting element interfacing an axial bearing surface of the sleeve, wherein an outer diameter D of the cutting element and a radial length T of a substantially planar portion of the axial bearing surface of the sleeve have the following relationship: (1/25)D?T?(1/4)D.

Abstract: A drill bit has a bit body, a plurality of blades extending radially from the bit body, wherein each blade comprises a leading face and a trailing face, a plurality of cutter pockets disposed on the plurality of blades, at least one rolling cutter, wherein each rolling cutter is disposed in one of the cutter pockets, and wherein each rolling cutter comprises a cutting face, a cutting edge, an outer circumferential surface, and a back face. A back retainer is disposed adjacent to the back face, wherein the back retainer protrudes partially into the rolling cutter along a rotational axis of the rolling cutter, and a front retainer is disposed adjacent to the at least one rolling cutter on the leading face of the blade. Each front retainer has a retention end, wherein the retention end is positioned adjacent to a portion of the cutting face of each rolling cutter, and an attachment end, wherein the attachment end is attached to a portion of the blade.

Abstract: Polycrystalline diamond constructions comprises a diamond body attached to a metallic substrate, and having an engineered metal content. The body comprises bonded together diamond crystals with a metal material disposed interstitially between the crystals. A body working surface has metal content of 2 to 8 percent that increases moving away therefrom. A transition region between the body and substrate includes metal rich and metal depleted regions having controlled metal content that provides improved thermal expansion matching/reduced residual stress. A point in the body adjacent the metal rich zone has a metal content that is at least about 3 percent by weight greater than that at a body/substrate interface. The metal depleted zone metal content increases gradually moving from the body, and has a thickness greater than 1.25 mm. Metal depleted zone metal content changes less about 4 percent per millimeter moving along the substrate.

Abstract: A cutting structure may include an outer support element; and an inner rotatable cutting element comprising a cutting surface at its upper end; wherein the inner rotatable cutting element comprises at least one line contact along a circumferential side surface thereof and/or at least one point contact at a bottom face thereof.