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 cutter for a drag bit may include a substrate and an ultrahard layer on an end surface of the substrate. The ultrahard layer may include an exposed surface having at least three depressions extending from an interior of the exposed surface radially outward to a peripheral edge formed between the working surface and a side surface of the ultrahard layer, the at least three depressions separated from each other by at least three raised regions forming an apex of the exposed surface, the at least three raised regions connected to each other proximate the central axis and extending from proximate the central axis to the peripheral edge. Other working surfaces are also included.

Abstract: A tool including a body defining a pocket, a cutting element in the pocket, at least one projection between an outside surface of the cutting element and an inside surface of the pocket, and a braze material between the cutting element and the pocket fixing the cutting element to the pocket.

Abstract: A cutting element has a sleeve with a first inner diameter and a second inner diameter, where the second inner diameter is larger than the first inner diameter and located at a lower axial position than the first inner diameter. A rotatable cutting element having an axis of rotation extending therethrough is at least partially disposed within the sleeve. The rotatable cutting element has a cutting face and a body extending axially downward from the cutting face, at least one hole extending from an outer surface of the body toward the axis of rotation, and a locking device disposed in each hole. The locking device protrudes from the hole to contact the second inner diameter of the sleeve, thereby retaining the rotatable cutting element within the sleeve.

Abstract: A cutting element includes a polycrystalline diamond layer having a cutting face and a diamond layer side surface, a substrate attached to the polycrystalline diamond layer, the substrate having a bottom surface and a substrate side surface, an interface between the diamond layer and the substrate, and a mask covering at least the bottom surface and the substrate side surface of the cutting element.

Abstract: A cutting element is provided having a substrate and an ultra hard material cutting layer over the substrate. The cutting layer includes a surface portion for making contact with a material to be cut by the cutting element. The surface portion in cross-section has a curvature that has a varying radius of curvature. A bit incorporating such a cutting element is also provided.

Abstract: A cutting element may include a substrate, an upper surface of the substrate including a crest, the crest transitioning into a depressed region, and an ultrahard layer on the upper surface, thereby forming a non-planar interface between the ultrahard layer and the substrate. A top surface of the ultrahard layer includes a cutting crest extending along at least a portion of a diameter of the cutting element, the top surface having a portion extending laterally away from the cutting crest having a lesser height than a peak of the cutting crest.

Abstract: A method of re-processing used TSP material layers to form cutting elements, bits with such cutting elements mounted on their bodies, and bits having re-processed TSP material layers attached to their bodies, as well as such cutting elements and bits are provided. The method includes providing a used TSP material cutting element having a TSP material layer and substrate, or a bit having a TSP material layer attached to the bit, removing the used TSP material layer from the cutting element or bit, cutting the used TSP material layer to a new shape, if necessary, optionally re-leaching the used TSP layer and re-using the TSP material layer to form a cutting element, or in forming a bit body. The formed cutting element may be mounted on a bit body.

Abstract: A fixed cutter drill bit including a bit body having a plurality of primary blades extending radially from a bit center area, wherein the bit center area includes a partial connection between at least two of the plurality of primary blades. The fixed cutter drill bit further including at least one cutter disposed on at least one of the blades. Additionally, a method of designing a fixed cutter drill bit includes modeling the fixed cutter drill bit, the fixed cutter drill bit including a plurality of primary blades extending radially from a bit center area, wherein the plurality of primary blades includes a plurality of cutters. The method further including determining a center of an innermost cutter on each primary blade, creating a partial connection between the primary blades, and outputting the model of the fixed cutter drill bit.

Abstract: Polycrystalline diamond composites comprise a polycrystalline diamond body having a plurality of ultra-hard discrete regions dispersed within a polycrystalline diamond second region. The plurality of discrete regions has an density different from of the polycrystalline diamond second region. A metallic substrate can be joined to the body. The discrete regions can be relatively more thermal stable than, have a higher diamond density than, and/or may comprise a binder material that is different from the polycrystalline diamond second region. Polycrystalline diamond composites can be formed by combining already sintered granules with diamond grains to form a mixture, and subjecting the mixture to high pressure/high temperature conditions, wherein the granules form the plurality of discrete regions, or can be made by forming a plurality of unsintered granules, combining them with diamond grains to form a mixture, and then subjecting the mixture to first and second high pressure/high temperature conditions.

Abstract: A cutting element for a drill bit includes an outer support element and an inner rotatable cutting element, a portion of which is disposed in the outer support element, where the inner rotatable cutting element has a body with a non-planar cutting face.

Abstract: Diamond bonded constructions comprise a diamond body attached to a substrate, wherein the body includes a first diamond bonded volume, and a second diamond bonded volume attached thereto. The second volume may be provided in the form of a powder or a presintered mass prior to attachment, and the first volume may be provided in the form of presintered pieces when combined with the second volume. The first volume diamond volume content is greater than about 94 percent, and is the same or greater than that of the second volume. The first volume is sintered during a first HPHT process, and the second volume is sintered and/or attached to the first volume during a second HPHT process. The first HPHT pressure is greater than the second HPHT pressure. The substrate is not an infiltration substrate used to form the first diamond volume. The diamond body may be thermally stable.

Abstract: Diamond bonded construction comprise a diamond body attached to a support. In one embodiment, an initial substrate used to sinter the body is interposed between the body and support, and is thinned to less than 5 times the body thickness, or to less than the body thickness, prior to attachment to the support to relieve stress in the body. In another embodiment, the substrate is removed after sintering, and the body is attached to the support. The support has a material construction different from that of the initial substrate, wherein the initial substrate is selected for infiltration and the support for end use properties. The substrate and support include a hard material with a volume content that may be the same or different. Interfaces between the body, substrate, and/or support may be nonplanar. The body may be thermally stable, and may include a replacement material disposed therein.

Abstract: A cutting tool cutting tool may include a tool body having a plurality of blades extending radially therefrom; and a plurality of rotatable cutting elements mounted on at least one of the plurality of blades, wherein the plurality of rotatable cutting elements are mounted on the at least one blade in a nose and/or shoulder region of the cutting tool at a side rake angle ranging from about 10 to about 30 degrees or ?10 to about ?30 degrees.

Abstract: A drill bit includes a bit body, a plurality of blades extending radially from the bit body, a plurality of cutter pockets disposed on the plurality of blades, at least one rolling cutter disposed in one of the cutter pockets, wherein each rolling cutter has a substrate, a cutting face, a cutting edge, and a side surface, and at least one blocker positioned adjacent to each of the at least one rolling cutters on a leading face of the blade, wherein each blocker has a retention end and an attachment end. The retention end of each blocker is positioned adjacent to a portion of the cutting face of each rolling cutter to retain the rolling cutter in the cutter pocket and the attachment end is attached to a portion of the blade.

Abstract: Methods for manufacturing a matrix tool body comprising placing a first matrix material within a first region of a mold cavity proximate a surface of the mold. A second matrix material may be placed within a second region of the mold cavity positioned inwardly of the first matrix material. The first matrix material and the second matrix material comprise a plurality of hard particles. The plurality of hard particles of the second matrix material have a median particle size that is less than the median particle size of the first matrix material. The plurality of hard particles of the first matrix material and the second matrix material are infiltrated with an infiltration binder to form the tool body. Also included are tool bodies having one or more regions proximate a surface of the tool body comprising an erosion resistant matrix material and/or a wear resistant matrix material.

Abstract: A cutting element assembly includes a rotatable cutting element having an axis of rotation extending axially therethrough, a cutting face and a body extending axially downward from the cutting face, at least one retention mechanism disposed adjacent to the rotatable cutting element, and a first magnet disposed at a back face of the rotatable cutting element.

Abstract: A cutting tool may include a tool body having a plurality of blades extending radially therefrom; each of the plurality of blades having a plurality of cutter pockets formed therein; and at least one rotatable cutting element having a cutting table with a convex cutting surface mounted in at least one of the plurality of cutter pockets, wherein the at least one rotatable cutting element is mounted in a nose or shoulder region of the at least one of the plurality of blades.

Abstract: Methods for manufacturing a matrix tool body comprising placing a first matrix material within a first region of a mold cavity proximate a surface of the mold. A second matrix material may be placed within a second region of the mold cavity positioned inwardly of the first matrix material. The first matrix material and the second matrix material comprise a plurality of hard particles. The plurality of hard particles of the second matrix material have a median particle size that is less than the median particle size of the first matrix material. The plurality of hard particles of the first matrix material and the second matrix material are infiltrated with an infiltration binder to form the tool body. Also included are tool bodies having one or more regions proximate a surface of the tool body comprising an erosion resistant matrix material and/or a wear resistant matrix material.

Abstract: A cutter for a fixed cutter drill bit including a substrate and an ultrahard material layer disposed on an end surface of the substrate, the ultra hard material layer having an upper surface opposite the substrate end surface and a peripheral surface such that the upper surface intersects the peripheral surface along a peripheral edge. The peripheral edge continuously increases and decreases in height as measured from a plane perpendicular to a longitudinal axis of the cutter.