A reamer for drill string pullback of a horizontal directional drill includes a shaft portion defining a central axis and a first end configured for attachment with a drill string of the horizontal directional drill. A plurality of vanes extend radially from an outer periphery of the shaft, each of the plurality of vanes defining an outer peripheral tooth base surface. On each of the plurality of vanes, a plurality of cutter teeth are individually and removably secured along the outer peripheral tooth base surface thereof, each one of the plurality of cutter teeth including a body and a PDC insert manufactured separately from the body and joined therewith. Each cutter tooth of the plurality is coupled to the respective one of the plurality of vanes by a removable fastener extending at least partially through the cutter tooth and at least partially through the one of the plurality of vanes.

A cutting tool includes a body configured to rotate about a longitudinal axis, a blade connected to the body, and a pre-formed segment. The blade extends away from the body and includes a recess formed in a leading face of the blade. The pre-formed segment is disposed in the recess adjacent to the leading face of the blade. The pre-formed segment is connected to the blade. The pre-formed segment includes a cutter pocket therein, the cutter pocket having a sidewall and a base.

Methods for attaching cutting elements to an earth-boring bit rely on keying the cutting elements inside cavities formed in the earth-boring bit. The attachment methods may involve specific shapes of the cutting elements and the cavities in which the cutting elements are received, and/or mechanical retainers. Preferably, the blade of the earth-boring bit is thicker around the opening in the edge of the blade than when the cavity is shaped for receiving a cutting element that has a circular cross-section.

Methods for attaching cutting elements to an earth-boring bit rely on keying the cutting elements inside cavities formed in the earth-boring bit. The attachment methods may involve specific shapes of the cutting elements and the cavities in which the cutting elements are received, and/or mechanical retainers. Preferably, the blade of the earth-boring bit is thicker around the opening in the edge of the blade than when the cavity is shaped for receiving a cutting element that has a circular cross-section.

An earth-boring tool includes a body, a plurality of fixed blades, a first plurality of cutting elements secured to the plurality of fixed blades, a plurality of removable blade assemblies removably coupled to the body, and a second plurality of cutting elements secured to the plurality of removable blade assemblies, each cutting element of the second plurality of cutting elements exhibiting an aggressiveness that is less than an aggressiveness of each cutting element of the first plurality of cutting elements. A method of forming an earth-boring tool includes forming a body and a plurality of fixed blades extending from the body, securing a first plurality of cutting elements to the plurality of fixed blades, removably coupling at least one removable blade assembly to the body, and securing a second plurality of cutting elements to the at least one removable blade assembly.

An earth-boring tool includes a body, a plurality of fixed blades, a first plurality of cutting elements secured to the plurality of fixed blades, a plurality of removable blade assemblies removably coupled to the body, and a second plurality of cutting elements secured to the plurality of removable blade assemblies, each cutting element of the second plurality of cutting elements exhibiting an aggressiveness that is less than an aggressiveness of each cutting element of the first plurality of cutting elements. A method of forming an earth-boring tool includes forming a body and a plurality of fixed blades extending from the body, securing a first plurality of cutting elements to the plurality of fixed blades, removably coupling at least one removable blade assembly to the body, and securing a second plurality of cutting elements to the at least one removable blade assembly.

A downhole tool includes a blade coupled to a body. The body and blade rotate about a longitudinal axis. A pre-formed faceplate is connected to the blade and partially defines a cutter pocket therein. Another portion of the cutter pocket is defined by the blade. The cutter pocket includes a sidewall and a base, with the sidewall formed by the blade and the pre-formed faceplate, and the base formed by the blade. The pre-formed faceplate includes a pre-formed hardfacing element. A downhole tool includes a blade coupled to a body. The body and blade rotate about a longitudinal axis. A pre-formed segment is connected to the blade and has a cutter pocket therein. The cutter pocket includes a sidewall and a base, and a cutting element is coupled to the pre-formed segment and within the cutter pocket. The pre-formed segment is optionally made of a different material than the blade and has increased wear and/or erosion resistance compared to the blade.

A downhole tool includes a blade coupled to a body. The body and blade rotate about a longitudinal axis. A pre-formed faceplate is connected to the blade and partially defines a cutter pocket therein. Another portion of the cutter pocket is defined by the blade. The cutter pocket includes a sidewall and a base, with the sidewall formed by the blade and the pre-formed faceplate, and the base formed by the blade. The pre-formed faceplate includes a pre-formed hardfacing element. A downhole tool includes a blade coupled to a body. The body and blade rotate about a longitudinal axis. A pre-formed segment is connected to the blade and has a cutter pocket therein. The cutter pocket includes a sidewall and a base, and a cutting element is coupled to the pre-formed segment and within the cutter pocket. The pre-formed segment is optionally made of a different material than the blade and has increased wear and/or erosion resistance compared to the blade.

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 drill assembly (10) for use in trenchless subterranean boring, comprising: a drill shoe (20) having a body with a posterior portion (30) and an anterior portion (22), the latter defining a recess while the former comprises drill bits (32) disposed on a front end (34), opposing lateral sides, and flanks to assist the shoe (20) in acting as both pilot bore drilling tool and as reaming tool; a drill head (50) demount ably mounted to tire drill shoe (20) via tire recess and in communication with directional guidance means; a string of connectable drill rods (80), having a bailing end (82) and a leading end (84) when connected, and through which a drilling solution can be pumped towards tire drill shoe (20); a coupling (86) for linking tire leading end (84) to said drill head (50); and a connector (88) for connecting the trailing end (82) to a vehicle. The invention extends to a drill shoe (20) and a method of use and manufacture thereof.