Drill bit vibration data for lateral, axial, and torsional directions of a drill bit is collected for a simulated or deployed drill bit for visualization of 3D coupled vibration. A frequency converter transforms the drill bit vibration data into frequency vibration data. A drill bit analyzer identifies local maxima (“peaks”) in the frequency vibration data in each of the lateral, axial, and torsional directions. Common peaks across all 3 directions with sufficiently high frequency and sufficiently high bit rotation speed are indicated as 3D coupled vibration. A drill bit data visualizer uses the indications of 3D coupled vibration in addition to the vibration data and frequency vibration data to generate visualizations of 3D coupled vibration in the drill bit.

Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.

Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.

A cutting device for use in a drill bit has a body including an ultrahard material. The body has a top surface, a front surface, and at least one lateral surface adjacent the top surface. The lateral surface is oriented at a surface angle relative to the top surface between 30 and 150 degrees. One or more locking features are located on the lateral surface.

A cutting device for use in a drill bit has a body including an ultrahard material. The body has a top surface, a front surface, and at least one lateral surface adjacent the top surface. The lateral surface is oriented at a surface angle relative to the top surface between 30 and 150 degrees. One or more locking features are located on the lateral surface.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

A drill bit having reinforced binder zones and method of forming same are disclosed. The method includes the steps of mixing reinforcing particles with a binder-reinforcing material, placing the mixture of reinforcing particles and binder-reinforcing material in a mold used in forming a body of the drill bit, placing a universal binder in the mold, and heating the mold. The binder-reinforcing material is infiltrated with the universal binder which thereby forms reinforced binder zones.

A drill bit for cutting a hole in a formation. The drill bit has a shank and a crown. The crown has a plurality of crown portions that are spaced about an operative circumference of the drill bit. The shank and crown cooperate to define an interior space that receives water or other drilling fluid. Each crown portion has two longitudinal edges, an outer surface, at least one inner surface and a cutting face. The crown has a base surface that is spaced from the cutting faces of the crown portions and cooperates with the inner surface of each of the two crown portions to define a slot.

In accordance with embodiments of the present disclosure, systems and methods for manufacturing a macroscopically reinforced metal-matrix composite (MMC) fixed-cutter bit are provided. The reinforced drill bit may include a bit body constructed from an infiltrated MMC material and featuring several blade portions extending radially outward and downward from a shank of the drill bit. These blade portions are designed for contacting a subterranean formation. The drill bit also includes the shank, which is coupled to an end of the bit body opposite the blade portions, to connect the bit body to an upstream component of a drill string. The drill bit further includes a number of macroscopic bit reinforcements that are at least partially enclosed within the bit body. These bit reinforcements are each disposed in and aligned substantially with a corresponding blade portion of the bit body.

In accordance with embodiments of the present disclosure, systems and methods for manufacturing a macroscopically reinforced metal-matrix composite (MMC) fixed-cutter bit are provided. The reinforced drill bit may include a bit body constructed from an infiltrated MMC material and featuring several blade portions extending radially outward and downward from a shank of the drill bit. These blade portions are designed for contacting a subterranean formation. The drill bit also includes the shank, which is coupled to an end of the bit body opposite the blade portions, to connect the bit body to an upstream component of a drill string. The drill bit further includes a number of macroscopic bit reinforcements that are at least partially enclosed within the bit body. These bit reinforcements are each disposed in and aligned substantially with a corresponding blade portion of the bit body.