A cutting element includes a body, a non-planar cutting face formed on a first end of the body, and an edge formed around a perimeter of the cutting face. The cutting face includes a central raised portion, and the edge has an edge angle defined between the cutting face and a side surface of the body. The edge angle varies around the perimeter of the cutting face and includes an acute edge angle defined by a portion of the cutting face extending downwardly from the edge to a depth from the cutting angle. The portion of the edge defining the acute edge angle may be directly adjacent: a side surface of the cutting element; a bevel of the cutting element; or a flat region at the perimeter of the cutting element or bevel.

A drill bit includes a bit body defining a bit rotational axis and a blade attached to the bit body. The apparatus also includes a cutter comprising a cutting arc on a cutting surface of the cutter, wherein the cutter comprises at least one relief comprising a straight edge and a curved edge having an end that interrupts the cutting arc.

A drill bit includes a bit body defining a bit rotational axis and a blade attached to the bit body. The apparatus also includes a cutter comprising a cutting arc on a cutting surface of the cutter, wherein the cutter comprises at least one relief comprising a straight edge and a curved edge having an end that interrupts the cutting arc.

Systems and methods include a computer-implemented method can be used to make drilling tools from new wurtzite boron nitride (w-BN) superhard material. An ultra-high-pressure, high-temperature operation is performed on pure w-BN powder to synthesize w-BN and cubic boron nitride (c-BN) compact having a first size greater than particles of the pure w-BN powder. The ultra-high-pressure, high-temperature operation includes pressurizing the w-BN powder to a pressure of approximately 20 Gigapascal, heating the w-BN powder at a heating rate of 100° C./minute and cooling the w-BN powder at a cooling rate of 50° C./minute. The compact is cut to a second size smaller than the first size using laser cutting tools. The cut compact is bonded metallurgically, mechanically, or both metallurgically and mechanically onto a tool substrate to form the drilling tool.

A cutting element for a drill bit can include a first layer of polycrystalline diamond, a second layer of polycrystalline diamond, wherein a boundary between the first layer and the second layer is nonplanar, and a substrate. The first and second layers can be formed from polycrystalline diamond of different grain sizes. One of the first and second layers can be leached of a catalyzing material. The first layer can be formed on a first substrate having a nonplanar surface feature, removed from the first substrate, and placed over the second layer to form the nonplanar boundary. The first layer can be leached of a catalyzing material prior to being applied to the second layer. A barrier layer can be placed between the first layer and the second layer to prevent sweeping of a catalyzing material into the leached first layer.

An example method for dynamic wear prediction for a drill bit with a cutting structure may include receiving at a processor of an information handling system an unworn profile of the cutting structure and a diamond distribution of the cutting structure. The diamond distribution may include a three-dimensional diamond distribution characterized by radial and axial position on the drill bit. The method may include calculating a final predicted wear profile of the cutting structure based, at least in part, on the unworn profile and the diamond distribution. The method also may include calculating iterations of intermediary wear profiles based, at least in part, on the previous wear profile and the diamond distribution. The final predicted wear profile may indicate a fully worn portion of the cutting structure. A usable life for the drill bit may be determined based, at least in part, on the final predicted wear profile.

An example method for dynamic wear prediction for a drill bit with a cutting structure may include receiving at a processor of an information handling system an unworn profile of the cutting structure and a diamond distribution of the cutting structure. The diamond distribution may include a three-dimensional diamond distribution characterized by radial and axial position on the drill bit. The method may include calculating a final predicted wear profile of the cutting structure based, at least in part, on the unworn profile and the diamond distribution. The method also may include calculating iterations of intermediary wear profiles based, at least in part, on the previous wear profile and the diamond distribution. The final predicted wear profile may indicate a fully worn portion of the cutting structure. A usable life for the drill bit may be determined based, at least in part, on the final predicted wear profile.

A drill bit includes a bit body defining a rotational axis, a plurality of blades on the bit body, a plurality of cutting elements on the plurality of blades, each cutting element defining a sweep profile about the rotational axis, a first depth of cut controller (DOCC) movably secured to one of the plurality of blades and movable in response to contact by a formation when drilling, and a second DOCC movably secured to the one of the plurality of blades, the second DOCC coupled to the first DOCC such that movement of the first DOCC changes a height of the second DOCC relative to a height of the first DOCC.

A drill bit includes a bit body defining a rotational axis, a plurality of blades on the bit body, a plurality of cutting elements on the plurality of blades, each cutting element defining a sweep profile about the rotational axis, a first depth of cut controller (DOCC) movably secured to one of the plurality of blades and movable in response to contact by a formation when drilling, and a second DOCC movably secured to the one of the plurality of blades, the second DOCC coupled to the first DOCC such that movement of the first DOCC changes a height of the second DOCC relative to a height of the first DOCC.

A cutting element comprising a cylindrical substrate; a table bonded to the cylindrical substrate; at least one tooth with a reduced projected cutting area on a periphery of the table; and a plurality of undulating cutting ridges on a top of the table. The table can have a working surface and at least one lateral surface, and a chamfer formed therebetween. The working surface can be a non-planar working surface. For a given weight on the bit, the cutter will sink into the rock deeper which can lead to better stability and more effective rock removal.