Abstract: Composite constructions comprise a plurality of granules that are arranged together in a randomly-oriented manner. The granules each comprise an ordered arrangement of a first material phase and a second material phase, wherein the first and second material phases are each continuous, and each occupy different and distinct regions of the granule. At least a portion of the first and second material phases of each granule are in contact with one another. The first material phase comprises a material selected from the group consisting of cermet materials, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof. The second material phase comprises a material that is relatively softer, e.g., more ductile, than the first material phase.

Abstract: An earth boring bit has at least one rotatable cone with a gage surface that engages a sidewall of a wellbore as the bit rotates. The gage surface has hardfacing bars spaced circumferentially apart from each other. A first group of the hardfacing bars extends from the inner edge of the gage surface to gage sides of the heel row cutting elements. A second group of the hardfacing bars extends from the inner edge of the gage surface to spaces between the heel row cutting elements, forming trimmer cutting elements. The hardfacing bars are made up of carbide particles in a metallic matrix.

Abstract: The present invention is directed to a drill bit with non-cutting erosion resistant inserts. In one illustrative embodiment, the apparatus comprises a matrix drill bit body comprising a plurality of blades, a plurality of cutting elements positioned on each of the blades, the cutting elements defining a plurality of web regions, and a plurality of spaced apart, non-cutting erosion resistant inserts positioned along a face of at least one of the blades, at least a portion of each of the non-cutting erosion resistant inserts being positioned in front of one of the web regions.

Abstract: An auxiliary cutting plate (10) for a multi-cutting plate drill bit (2) has a body (44) for fixing into a slot in the drill bit (2) and a profiled tip (46). The body (44) has a central longitudinal axis and the profiled tip (46) protrudes from one end of the body (44). The profiled tip (46) has a cutting edge (62) defined by a transition between a rake face (64) and a relief face (66). The rake face (64) and the relief face (66) each slope axially rearward from opposite sides of the cutting edge (62). The angle of inclination ? of at least a portion of the rake face (64), measured from a plane perpendicular to the longitudinal axis, decreases with increasing distance from the cutting edge (62).

Abstract: A superabrasive cutting element including a diamond or other superabrasive material table having a peripheral cutting edge defined by at least two adjacent chamfers having an arcuate surface substantially tangent to each of the at least two chamfers interposed therebetween. Methods of producing such superabrasive cutting elements and drill bits equipped with such superabrasive cutting elements are also disclosed.

Abstract: A cutting insert 1, 1?, comprising opposite insert planes E1, E2 of a base 2 of one base area 3 wherein a conical surface section 4a of a lateral face 4 and the base area 3 facing the same form an acute angle alpha while forming a cutting edge 5, while a planar surface section 4b of the same lateral face 4 forms an obtuse angle beta with the opposite base area 3. The cone axis 6 of the conical surface area 4a lying in the insert plane E1, E2 runs off-set in parallel to the center insert axis 7 lying in the same insert plane E1, E2 while forming an off-center arcuate profile of the cutting edge 5. A milling cutter 17 comprising a number of such cutting inserts 1, 1? is characterized in that a cutting insert 1, 1? preferably disposed on the periphery of the center line M of a tool support 16 is off-set from the center line M by an angle phi equal to 5±3 degrees.

Abstract: A tungsten carbide compact of an earth boring bit has a cutting tip that is generally chisel-shaped with substantially flat flanks converging to an elongated crest. One of the flanks is smaller and has a greater included angle relative to the axis of the compact than the other flank. Shoulders extend from opposite ends of the crest. One shoulder has a radius of curvature that is smaller than the other shoulder.

Abstract: A rolling cone drill bit is provided that has gage inserts on the first row from the bit axis to cut to full gage diameter that have a cutting portion enhanced with a layer of super abrasive material. The gage cutting surface has a center axis that is canted to be more normal to the gave curve such that its point of contact at gage is away from the thinner portion of the layer of super abrasive material.

Abstract: The present invention generally relates to a cutting insert for use with wellbore milling tools. The cutting insert forms an angle between a milling surface of the insert and a surface of the tool that the insert is attached to in order to provide the proper cutting incline, and substantially perpendicular sides of the insert relative to the milling surface of the insert provide continuous support for the milling surface. In addition, the inserts can comprise spacers and legs that evenly distribute bonds formed between inserts and bonds formed between the inserts and the surface of the tool, respectively. Selecting the dimensions of the spacers and legs alters the strength of the bonds.

Abstract: A drill bit that includes a bit body, at least one roller cone attached to the bit body and able to rotate with respect to the bit body, a plurality of cutting elements disposed on the at least one roller cone, and a barrel axis is disclosed. At least one of the plurality of cutting elements includes a first area defining a secondary wear surface, wherein the first area is formed as a convex surface on the trailing edge, a second area proximate the first area defining a main wear surface, wherein the second area is formed as a convex curved surface having a radius of curvature substantially equal to a radius of a borehole, and a third area defining a spherical cutting surface. Further, at least one of the plurality of cutting elements includes a non-spherical transition zone disposed between the third area and the first and second areas, wherein the barrel axis intersects the transition zone.

Abstract: A superabrasive cutting element for use with a drill bit for drilling subterranean formations and having a superabrasive table, or cutting face, in which a conglomerate of superabrasive particles is dispersed and bonded, or sintered, and in which at least one exposed cutting region of the superabrasive table develops a rough, asperital surface for improving the cutting efficiency of the drill bit, particularly in but not limited to relatively hard, relatively nonabrasive formations. The superabrasive table may include superabrasive particles of substantially differing size, or quality or a combination of differing size and quality. A rotary drill bit including cutting elements embodying the present invention is also disclosed.

Abstract: Roller cone bits include a steel bit body having a leg extending therefrom. A steel cone is disposed on the leg and includes steel cutting elements projecting outwardly therefrom. One of the cutting elements comprises a steel base integral with the cone and that projects therefrom. A cutting element end is attached to the base portion and extends to form a cutting element tip. The base and end portions are attached when the cone base are in a preexisting rigid state. The end portion comprises a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.

Abstract: Disclosed is a rolling cone cutter and drill bit employing multiple inserts retained as a cluster in an aperture in the cone cutter. Apertures in which the insert clusters are retained are multilobed apertures formed by intersecting bores formed in the cone steel. The apertures may also be created by forming spaced apart bores and milling regions of the cone steel that extends between the bores. The inserts in a cluster may be retained within the aperture to differing depths, may extend above the cone steel to differing extension lengths, and may have cutting portions having a variety of shapes. The inserts in a cluster may be made of different materials in order to optimize cutting duty.

Abstract: A rotary drill bit is used both for milling a casing window and drilling a lateral borehole into subterranean earthen materials, without the prior need of having separate drill bits for milling of the casing and for drilling of the borehole. The rotary drill bit is lowered into a casing set within a borehole; and the drill bit is rotated to engage an inner surface of the casing. A first set of cutting elements on the drill bit remove casing material to mill a casing window. The drill bit is then moved through the casing window so that a second set of cutting elements on the drill bit create a lateral wellbore in subterranean earthen material.

Abstract: Cutting elements having coarse grain substrates and ultra hard material layers are provided. The substrates are formed from coarse grain size particles of tungsten carbide. A method of forming such cutting elements and a drag bit incorporating such cutting elements are also provided.

Abstract: A drill bit with rolling cone cutters for drilling a borehole in an earthen formation. The bit has a bit body, at least one leg depending from the bit body, a rolling cone rotatably mounted on the leg, the cone having a plurality of adjacent rows of cutters thereupon, at least one hole formed within the cone, the hole having a cylindrical wall, and a cutting element partially disposed within the hole, the cutting element having a cylindrical base which fits within the cylindrical wall of said hole, a shoulder which extends outward from the base of the cutting element, and an exposed cutting end extending from the shoulder, the cutting end being substantially symmetrical about a longitudinal axis of the cutting element.

Abstract: A rolling cone drill bit is provided that has gage inserts on the first row from the bit axis to cut to full gage diameter that have a cutting portion enhanced with a layer of super abrasive material. The gage cutting surface has a center axis that is canted to be more normal to the gage curve such that the its point of contact at gage is away from the thinner portion of the layer of super abrasive material.

Abstract: A rotary-cutter Earth-penetrating bit in which a given track of bottom hole is attacked by inserts of two different types, e.g. chisel-shaped and pointed, wider and narrower, higher and shorter, and/or of different materials. The different types of inserts can both be included within a single row of a cone.

Abstract: A superabrasive cutting element including a diamond or other superabrasive material table having a peripheral cutting edge defined by at least two adjacent chamfers having an arcuate surface substantially tangent to each of the at least two chamfers interposed therebetween. Methods of producing such superabrasive cutting elements and drill bits equipped with such superabrasive cutting elements are also disclosed.

Abstract: An abrasive tool insert includes (a) a substrate having a support face that includes (1) an inner support table, (2) an outer shoulder having a width, Sw, and (3) a downwardly sloping interface from the support table to the shoulder, which interface has a slope angle, Sa. A continuous abrasive layer, integrally formed on the substrate support face, includes (1) a center having a height, Dc, (2) a diameter, Dd, (3) a periphery having a height, Dp, in contact with the shoulder and which periphery forms a cutting edge. Sw:Dd ranges from between 0 and about 0.5. For each Sa and Sw:Dd, Dc:Dp is selected so as to diminish residual stress in the abrasive layer.

Abstract: An earth-boring bit has a bit body, at least one cantilevered bearing shaft depending inwardly and downwardly from the bit body, and a cutter mounted for rotation on the bearing shaft. The cutter includes a plurality of teeth that are covered with a hardfacing layer. At least some of the teeth have a leading side that has a streamlined contour. The streamlined contour is generally conical in some of the embodiments. In others, the streamlined contour is defined by a corner between diverging inner and outer sections of the leading side.

Abstract: A percussion drill bit is provided that has at least two different pluralities of inserts extending from the bit head to better match the conditions seen on the bit head during drilling. The preferred embodiment has a plurality of large inserts with a polycrystalline diamond layer located at least in the gage row and a plurality of smaller inserts located at least in the inner rows.

Abstract: A non-uniform interface is formed between a polycrystalline ultra hard material layer and a cemented tungsten carbide substrate, or a polycrystalline ultra hard material layer and a transition layer, or a transition layer and a substrate of a cutting element. A first sheet made from an intermediate material is formed and embossed on one face forming a non-uniform pattern raised in relief on the face. The embossed sheet is placed on a face of a presintered substrate. An ultra hard material sheet is formed and embossed, forming a non-uniform face complementary to the non-uniform face on the sheet of intermediate material. The ultra hard material sheet is placed over the intermediate material sheet so that the complementary faces are adjacent to each other. The assembly of substrate and sheets is sintered in a HPHT process.

Abstract: A rotary drill bit for drilling subterranean formations configured with at least one protective structure proximate to the rotationally leading and trailing edges of a gage trimmer, wherein the at least one protective structure is positioned at substantially the same exposure as its associated gage trimmer. Particularly, the apparatus of the present invention may provide protection for gage trimmers during drilling, tripping, and/or rotation within a casing; i.e., when changing a drilling fluid. Protective structures may be configured and located according to anticipated drilling conditions including helix angles. In addition, a protective structure may be proximate to more than one gage trimmer while having a substantially equal exposure to each associated gage trimmer. Methods of use and a method of rotary bit design are also disclosed.

Abstract: A method for designing a drill bit that has at least one roller cone and a plurality of cutting elements, including selecting initial bit design parameters. Drilling simulations are then used to determine wear, and the simulated drill bit is changed to reflect the determined wear. Then, at least one design parameter is adjusted. The simulation, determination, change of the simulated drill bit, and adjustment may be repeated until at least one performance parameter of the drill bit is optimized. A drill bit can be designed using such a method.

Abstract: A thin layer of carbide containing an ultra-hard component, such as diamond, is applied to a formed compact for a drilling tool. The compact is then subjected to a high-temperature, high-pressure process to bond it to the added layer. This process allows the use of an underlying substrate which has a lower binder content than previously possible. The compact provides superior cutting ability, as even if the diamond-enhanced layer wears through, the carbide can provide enhanced hardness.

Abstract: In one embodiment, composite constructions of the invention are in the form of a plurality of coated fibers bundled together to produce a fibrous composite construction in the form of a rod. Each fiber has a core formed from a hard phase material, that is surrounded by a shell formed from a binder phase material. In another embodiment of the invention, monolithic sheets of the hard phase material and the binder phase material are stacked and arranged to produce a swirled composite in the form of a rod. In still another embodiment of the invention, sheets formed from coated fibers are arranged to produce a swirled composite. Inserts for use in such drilling applications as roller cone rock bits and percussion hammer bits, and shear cutters for use in such drilling applications as drag bits, that are manufactured using conventional methods from these composite constructions exhibit increased fracture toughness due to the continuous binder phase around the hard phase of the composites.

Abstract: Disclosed are a variety of arcuate-shaped inserts for drill bits, and in particular, for placement in rolling cone cutters of drill bits. The arcuate inserts include 360 degree or ring-shaped inserts, as well as inserts of smaller arcuate length. The arcuate inserts may include stress relieving discontinuities such that, upon assembly into the cone, the arcuate inserts fragment in a controlled and predicted manner into shorter arcuate lengths. The arcuate inserts are suitable for use in all surfaces of the rolling cone cutter, and in other locations in drill bits, and may have specialized cutting surfaces and material enhancements to enhance their cutting duty performance.

Abstract: Rotary tools or bits carry cutter element including pointed contact structures and elements for chipping, cutting, and breaking non-ductile materials such as rock. The cutter elements directly contact and cut through rock and other materials and have tapered contact structure ends. Rotary tools or bits for carrying the cutter elements carry fixed cutter elements, or have sockets for removable threaded or rotatable cutter elements, arranged in straight or curved rows on the head opposite a drill-string-engaging base of the tool. The tools also have radially-extending buttresses which help to protect the cutter elements from damage as a drill string and bit are withdrawn from a bore.

Abstract: Roller cone drilling wherein the bit optimization process equalizes the downforce (axial force) for the cones (as nearly as possible, subject to other design constraints). Bit performance is significantly enhanced by equalizing downforce.

Abstract: Disclosed is a rolling cone cutter and drill bit employing multiple inserts retained as a cluster in an aperture in the cone cutter. Apertures in which the insert clusters are retained are multilobed apertures formed by intersecting bores formed in the cone steel. The apertures may also be created by forming spaced apart bores and milling regions of the cone steel that extends between the bores. The inserts in a cluster may be retained within the aperture to differing depths, may extend above the cone steel to differing extension lengths, and may have cutting portions having a variety of shapes. The inserts in a cluster may be made of different materials in order to optimize cutting duty.

Abstract: Cutter elements for use in rolling cones rock bits are disclosed having a crown that includes multiple, spaced-apart cusps for enhancing formation removal by creating overlapping Hertzian contact zones. The cusps may be partially dome-shaped, berm shaped or otherwise. The cutter elements provide multiple cutting edges for engaging the formation and may have differing radii and extension length as suitable for particular applications.

Abstract: An earth-boring bit has a bit body, at least one cantilevered bearing shaft depending inwardly and downwardly from the bit body, and a cutter mounted for rotation on the bearing shaft. The cutter includes a plurality of teeth that are covered with a hardfacing layer. At least some of the teeth have a leading side that has a streamlined contour. The streamlined contour is generally conical in some of the embodiments. In others, the streamlined contour is defined by a corner between diverging inner and outer sections of the leading side.

Abstract: A cutting element for a drag-type drill bit comprises a cutter body having a generally cylindrical base section adapted for snug-fitting engagement in a socket of a drill bit body. The cutter body is secured to the bit body by brazing or other conventional attachment techniques. The cutter body further has a generally cylindrical cutting section integral with the base section. The cutting section has at least one inclined surface extending from a top surface of the cutting section partially the length of the generally cylindrical cutting section. The cutter body may comprise a sintered tungsten carbide and the top surface may comprise a layer of super hard material.

Abstract: The present invention generally relates to a cutting insert for use with wellbore milling tools. The cutting insert forms an angle between a milling surface of the insert and a surface of the tool that the insert is attached to in order to provide the proper cutting incline, and substantially perpendicular sides of the insert relative to the milling surface of the insert provide continuous support for the milling surface. In addition, the inserts can comprise spacers and legs that evenly distribute bonds formed between inserts and bonds formed between the inserts and the surface of the tool, respectively. Selecting the dimensions of the spacers and legs alters the strength of the bonds.

Abstract: The present invention provides a new drilling tool useful in machining hydraulic port seals for fluid power ports. The drilling tool drills the port hole to size in a solid material for the minor thread diameter in combination with forming the port in a single operation. The drilling tool has a tool holder having a rotational axis, a first drilling insert having cutting surfaces on a first side and a mounting surface on a second side, at least one second drilling insert having a predetermined cutting surface portion and a mounting portion which is mounted on the holder at a location from the rotational axis of the holder. The at least one second drilling insert has first and second portions which engage and machine a work piece in a drilling operation to form a spot face and a seal form.

Abstract: A method for forming a drill bit body is disclosed which comprises infiltrating powdered tungsten carbide with a binder alloy in a mold. The mold has therein at least one displacement adapted to form a mounting pad for a cutting element. The displacement comprises a substantially cylindrical body having a diameter selected to substantially conform to a radius of the cutting element and a projection adapted to form a relief groove under a position of a diamond table in the cutting element when the cutting element is mounted on the pad. The width of the relief groove is selected so that the relief groove extends back from an outer surface of the bit body at least about 40 percent of that portion of a thickness of the diamond table which does not extend past the outer surface.

Abstract: A rotary-cutter Earth-penetrating bit in which a given track of bottom hole is attacked by inserts of two different types, e.g. chisel-shaped and pointed, wider and narrower, higher and shorter, and/or of different materials. The different types of inserts can both be included within a single row of a cone.

Abstract: A hard material insert (1) for a tool, which is configured segmental and has a planar, polycrystalline diamond layer (2), which has a main cutting element (3) having a radius R in the layer plane and an opposing, at least segmental linear contact edge (4). The minimal radius of curvature K is greater than R/20 in a transition zones (X, X′) of the main cutting element (3) to the contact edge (4). The transition areas (X, X′) of lesser curvature are produced in post-processing.

Abstract: A cutting tip for a drilling tool includes a cemented carbide cutting base 11, a diamond element 12 supported by the cutting base 11, and a bonding layer formed between the cutting base 11 and the diamond element 12 in order to bond them. The bonding layer 13 includes diffusion layers S1 and S2 in which one or two or more metals selected from a group consisting of Fe, Ni, Co, Ti, Zr, W, V, Nb, Ta, Cr, Mo, and Hf diffuses into at least one of the cemented carbide or the diamond.

Abstract: A drill bit that includes a bit body, at least one roller cone attached to the bit body and able to rotate with respect to the bit body, and a plurality of cutting elements disposed on the at least one roller cone is disclosed. At least one of the plurality of cutting elements includes a first area defining a trailing edge, and a second area proximate the first area defining a main wear surface.. Further, an insert for a drill bit that includes a contact portion adapted to contact an earth formation, the contact portion including a first area defining a relieved trailing edge, and a second area defining a main wear surface, wherein a surface of the second area is a curved surface having a radius of curvature substantially equal to a radius of a borehole is also disclosed.

Abstract: An earth-boring bit comprises a bit body bit body in which are mounted a plurality of cutting structures inserts, wherein at least a portion of the cutting structures comprise diamond-impregnated inserts having a total thermal exposure of less than 25 minutes above 1500° F. The diamonds can be natural or synthetic diamond. The bit body itself may be diamond-impregnated, in which case it is preferred that the diamonds in the inserts make up at least 40% of the total diamond in the bit.

Abstract: A rolling cone drill bit is provided that has gage inserts on the first row from the bit axis to cut to full gage diameter that have a cutting portion enhanced with a layer of super abrasive material. The gage cutting surface has a center axis that is canted to be more normal to the gage curve such that the its point of contact at gage is away from the thinner portion of the layer of super abrasive material.

Abstract: A rotary cone bit, having a functionally-engineered surface of this invention, comprises a bit body having at least one leg extending therefrom, and a cone that is rotatably disposed on the leg. The cone typically comprises a plurality of cutting elements that project outwardly therefrom. The cutting elements comprises a cermet material selected from the group consisting of refractory metal carbides, nitrides, borides, carbonitrides and mixtures thereof. A functionally-engineered material is disposed over a surface portion of at least one of the cutting elements to form a wear resistant surface thereon. The wear resistant surface has a hardness that is different than that of the underlying cutting element. The wear resistant surface is provided by forming a conformable material mixture by combining one or more powders selected from the group consisting of cermets, carbides, borides, nitrides, carbonitrides, refractory metals, Co, Fe, Ni, and combinations thereof, with an applying agent.

Abstract: A hardfacing material is applied to cutting elements formed on the surface of cutters of an earth-boring bit. The hardfacing material forms the outer surface of the teeth, and also substantially forms scrapers on the shell of each of the cutters. The adding of the hardfacing material to the outer surface of the teeth and the forming of the scrapers is accomplished through welding. The hardfacing material is machined from its “as-welded” state to have a smoother surface finish.

Abstract: PCD and PCBN composite constructions have an ordered structure of two or more material phases that are combined together in a packed or interwoven configuration. One of the material phases is formed from materials selected from the group consisting of: polycrystalline diamond, polycrystalline cubic boron nitride; carbides, borides, nitrides, and carbonitrides from groups IVA, VA, and VIA of the Periodic Table; and mixtures thereof. Another material phase is preferably formed from a material having a degree of ductility that is higher than that of the first material phase. Example second material phase materials include those selected from the group consisting of cermets, Co, Ni, Fe, W, Mo, Cu, Al, Nb, Ti, Ta, and mixtures thereof.

Abstract: A polycrystalline diamond cutter and method of manufacturing a polycrystalline diamond cutter is disclosed. The method of manufacture comprising assembling a first substrate component, a second substrate component and diamond crystals into a desired configuration. The assembly is subjected to high temperature and high pressure conditions to cause the diamond crystals to bond to one another and to the first and second substrate components. The method forms a cutter having a single body of polycrystalline diamond bonded to the substrate components.

Abstract: The present invention relates to cutting tool insert consisting of a tungsten carbide based hard metal substrate and a coating. The hard metal consists of about 4-15 wt-% binder phase with face centered cubic structure and a composition of 35-65 wt-% Fe and 35-65 wt-% Ni in addition to dissolved elements. As a result, inserts have been produced with at least as good performance in machining as conventional state-of-the-art inserts with Co-based binder phase. The insert can be applied in milling and turning of low and medium alloyed steels as well as stainless steels.

Abstract: An insert for a rock bit that includes tungsten carbide particles, and a cobalt binder disposed around the particles, wherein a grain size of the tungsten carbide particles and a content of the cobalt binder are selected to provide a fracture toughness of at least about 18 ksi (in)0.5, a wear number of at least about 2, and a hardness of 85 to 87 Ra is disclosed.

Abstract: A cutting insert for a gauge row of a percussion drill bit includes a generally cylindrical mounting portion extending along a central axis and a cutting head extending from the mounting portion. The cutting head has an exposed surface forming a non-symmetrical dome shape such that the working portion of the cutting head is enlarged with respect to a standard dome shape and a trailing portion of the cutting head is reduced with respect to a standard dome shape. The cutting head has an inner edge and an outer edge. The exposed surface is non-symmetrical along a central plane which bisects the working portion and the trailing portion. The exposed surface is symmetrical in a second plane perpendicular to the central plane such that the exposed surface forms an arc of constant radius from the inner edge to the outer edge in the second plane.