Sleeve for a drilling insert and method for manufacturing the same

Abstract

A method of manufacturing a sleeve for a drilling insert includes shaping a stock to form a blank, and forming a flute in the blank to produce a sleeve configured to be mounted on a shaft of the drilling insert.

Description

Attorney Docket No. 066042-1962 -WO01SLEEVE FOR A DRILLING INSERT AND METHOD FOR MANUFACTURING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 693,268, filed September 11, 2024, to U.S. Provisional Application No. 63 / 772,894, filed March 17, 2025, and to U.S. Provisional Application No. 63 / 843,893, filed July 14, 2025, the entire contents of all of which are incorporated by reference herein.FIELD OF THE INVENTION

[0002] The present invention relates to a drill bit assembly including a drilling insert and a sleeve and a method of manufacturing the sleeve.SUMMARY OF THE INVENTION

[0003] In some aspects, the techniques described herein relate to a method of manufacturing a sleeve for a drilling insert, the method including shaping a stock to form a blank; and forming a flute in the blank to produce a sleeve configured to be mounted on a shaft of the drilling insert.

[0004] In some aspects, the techniques described herein relate to a drill bit assembly including a drilling insert including a body having a first end and a second end opposite the first end, the body including a cutting head positioned at the first end, a shank positioned at the second end, the shank configured to be coupled to a tool, and a shaft extending between the cutting head and the shank; and a sleeve formed by shaping a stock to form a blank, forming a flute in the blank to produce a sleeve, and straightening the sleeve, the sleeve mounted on the body to radially surround the shaft.

[0005] In some aspects, the techniques described herein relate to a drill bit assembly including a drilling insert including a body having a first end and a second end opposite the first end, the body including a cutting head positioned at the first end, a shank positioned at the second end, the shank configured to be coupled to a tool, and a shaft extending between the cutting head and the shank; and a sleeve mounted on the body to radially surround the shaft, the sleeve including multiple segments that are secured together to form a sleeve body and a plurality of sleeve lands wrapped helically around the sleeve body to define a flute.1MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0006] In some aspects, the techniques described herein relate to a drill bit assembly including a drilling insert including a body having a first end and a second end opposite the first end, the body including a cutting head positioned at the first end, a shank positioned at the second end, the shank configured to be coupled to a tool, and a shaft extending between the cutting head and the shank; and a sleeve mounted on the body to radially surround the shaft, the sleeve including an angle iron that is twisted about its length to form a sleeve body with a plurality of sleeve lands that wrap helically about the sleeve body to define a flute.

[0007] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of a drilling insert and a sleeve in accordance with an embodiment of the disclosure.

[0009] FIG. 2 is a cross-sectional view of the drilling insert and the sleeve taken along line 2-2 in FIG. 1.

[0010] FIG. 3 is a side view of the drilling insert of FIG. 1.

[0011] FIG. 4 is a flow chart illustrating a method of manufacturing the sleeve of FIG. 1.

[0012] FIG. 5A is a perspective view of exemplary stock to be used in the method of manufacturing illustrated in FIG. 4.

[0013] FIG. 5B is an end view of an exemplary blank formed in the method of manufacturing illustrated in FIG. 4.

[0014] FIG. 5C is a side view of an exemplary sleeve produced by the method of manufacturing illustrated in FIG. 4.

[0015] FIG. 6 is a flow chart illustrating an alternate method of manufacturing the sleeve of FIG. 1.

[0016] FIG. 7A is a perspective view of stock in a die to be used in the method of manufacturing illustrated in FIG. 6.2MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0017] FIG. 7B is another perspective view of the stock in the die during the method of manufacturing illustrated in FIG. 6.

[0018] FIG. 7C is a perspective view of a blank formed during the method of manufacturing illustrated in FIG. 6.

[0019] FIG. 7D is an end view of the blank formed during the method of manufacturing illustrated in FIG. 6.

[0020] FIG. 7E is a side view of a sleeve produced by the method of manufacturing illustrated in FIG. 6.

[0021] FIG. 8 is a flow chart illustrating an alternate method of manufacturing the sleeve of FIG. 1.

[0022] FIG. 9 is a perspective view of a sleeve produced by the method of manufacturing a sleeve illustrated in FIG. 8.

[0023] FIG. 10 is a flow chart illustrating an alternate method of manufacturing a sleeve of FIG. 1.

[0024] FIG. 11 A is an end view of exemplary stock to be used in the method of manufacturing illustrated in FIG. 10.

[0025] FIG. 1 IB is an end view of a partially complete blank formed during the method of manufacturing illustrated in FIG. 10.

[0026] FIG. 11 C is an end view of an exemplary blank formed by the method of manufacturing illustrated in FIG. 10.

[0027] FIG. 1 ID is a perspective view of an exemplary sleeve produced by the method of manufacturing illustrated in FIG. 10.

[0028] FIG. 12 is a flow chart illustrating an alternate method of manufacturing the sleeve of FIG. 1.

[0029] FIG. 13A is a cross-sectional view of an exemplary7blank formed by the method of manufacturing illustrated in FIG. 12.3MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0030] FIG. 13B is a cross-sectional view of another exemplary blank formed by the method of manufacturing illustrated in FIG. 12.

[0031] FIG. 13C is a cross-sectional view of another exemplary blank formed by the method of manufacturing illustrated in FIG. 12.

[0032] FIG. 13D is a perspective view of an exemplary sleeve produced by the method of manufacturing illustrated in FIG. 12.

[0033] FIG. 14 is a flow chart illustrating an alternate method of manufacturing the sleeve of FIG. 1.

[0034] FIG. 15A is a cross-sectional view of exemplary stock to be used in the method of manufacturing illustrated in FIG. 14.

[0035] FIG. 15B is a cross-sectional view of a partially complete blank formed during the method of manufacturing illustrated in FIG. 14.

[0036] FIG. 15C is a cross-sectional view of an exemplary blank formed by the method of manufacturing illustrated in FIG. 14.

[0037] FIG. 16 is a flow chart illustrating an alternate method of manufacturing the sleeve of FIG. 1.

[0038] FIG. 17 is a side view of part of an exemplary sleeve produced by the method of manufacturing illustrated in FIG. 16.

[0039] FIG. 18 is a flow chart illustrating an alternate method of manufacturing the sleeve of FIG. 1.

[0040] FIG. 19 is a perspective view of the drilling insert of FIG. 1 and another sleeve.

[0041] FIG. 20 is a perspective view of the sleeve of FIG. 19.

[0042] FIG. 21 is an exploded perspective view of the sleeve of FIG. 19.

[0043] FIG. 22 is a perspective view of an angle iron.4MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0044] FIG. 23 is a perspective view of another sleeve for use with the drilling insert of FIG. 1. the sleeve made from the angle iron of FIG. 22.

[0045] FIG. 24 is a perspective view of yet another sleeve for use with the drilling insert of FIG. 1, the sleeve made from two angle irons.

[0046] FIG. 25 is an end view of the sleeve of FIG. 24.DETAILED DESCRIPTION

[0047] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. As used herein, terms such as “approximately.” “substantially,” “about,” and the like are meant to encompass values within a rounding value and / or manufacturing tolerance of the value stated.

[0048] FIGS. 1-3 illustrate a drilling insert 10 and a sleeve 14 mounted on the drilling insert 10. The drilling insert 10 may also be referred to as a drill bit or a tunnel bit. Together, the drilling insert 10 and the sleeve 14 may be referred to as a drilling insert assembly, a drill bit assembly, or a tunnel bit assembly. The drilling insert 10 includes a body 18 and a cutting insert 22. The drilling insert 10 is configured for drilling relatively deep holes in a workpiece, such as concrete, concrete with rebar, brick, block, and other similar materials.

[0049] The body 18 has a first end 18 A, a second end 18B opposite the first end 18 A, and a length LI measured between the first end 18A and the second end 18B. The length LI may also be referred to as a total length or an overall length of the drilling insert 10. In some embodiments, the length LI may range between about 12 inches and about 24 inches. In other embodiments, the drilling insert 10 may be longer or shorter. The body 18 is configured to rotate about a central longitudinal axis Al that extends through the first end 18A and the second end 18B. The length LI is measured parallel to the central longitudinal axis AL The body 18 includes a cutting head 26 positioned at the first end 18A, a shank 30 positioned at the second end 18B, a shaft 34 extending between the cutting head 26 and the shank 30, and a groove 36 formed in between the shank 30 and the shaft 34. In the illustrated embodiment, the cutting head 26, the shank 30, and the shaft 34 are integrally formed as a5MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 single piece. In other embodiments, the cutting head 26, the shank 30, and / or the shaft 34 may be separate pieces that are secured (e.g., welded) together.

[0050] The cutting head 26 is configured to receive the cutting insert 22 and engage a workpiece for performing a cutting operation. The cutting head 26 has a first maximum outer diameter DI which is measured perpendicular to the central longitudinal axis Al. In the illustrated embodiment, the diameter of the cutting head 26 continuously increases from the shaft 34 to the first maximum outer diameter DI . In other embodiments, the diameter of the cutting head 26 may abruptly increase (e.g., via one or more steps) or the diameter of the cutting head 26 may increase in a non-continuous manner. Additionally, with the cutting insert 22 coupled to the cutting head 26. the cutting insert 22 and the cutting head 26 have a combined length L4. The combined length L4 is measured parallel to the central longitudinal axis Al . The combined length L4 is defined from the portion of the cutting head 26 that is adjacent, or touching, the shaft 34 to a tip of the cutting insert 22. In some embodiments, the combined length L4 of the cutting insert 22 and the cutting head 26 may be less than a quarter (i. e. , 25%) of the total length LI of the drilling insert 10. In other embodiments, the combined length L4 of the cutting insert 22 and the cutting head 26 may be less than a fifth (i.e., 20%) of the total length LI of the drilling insert 10. In the illustrated embodiment, the combined length L4 of the cutting insert 22 and the cutting head 26 is less than 10% of the total length L 1 of the drilling insert 10.

[0051] The shank 30 is configured to be inserted in and engaged by any number of different tools, adapters, or components to receive torque from the tool, adapter, or component to rotate the bit. For example, the drilling insert 10 may be utilized with a power tool, such as a driver or hammer drill including a socket. The shank 30 is the portion of the body 18 that is inserted into and supported in the power tool. In the illustrated embodiment, the shank 30 is configured as an SDS-style shank, such as an SDS shank, and SDS Plus shank, or an SDS Max shank, and includes slots 30A and detent recesses 30B for receiving coupling features from a power tool. For example, a quick-release structure, such as a balldetent mechanism, may be employed to axially secure the bit 10 to the driver. In other embodiments, the shank 30 may be formed as a hex shank that is configured to engage a hexshaped socket in a power tool. In still other embodiments, the shank 30 may have other configurations suitable for other styles of chucks or adapters.6MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0052] The shank 30 has a shank length L2 and a second maximum outer diameter D2. The shank length L2 is measured parallel to the central longitudinal axis Al. The second maximum outer diameter D2 is measured perpendicular to the central longitudinal axis Al. In the illustrated embodiment, the shank length L2 is no more a quarter (i.e., 25%) of the total length LI of the drilling insert 10. In some embodiments, the shank length L2 may be no more than a fifth (i.e., 20%) of the total length LI of the drilling insert 10. In the illustrated embodiment, the second maximum outer diameter D2 is smaller than the first maximum outer diameter DI. For example, the first maximum outer diameter DI of the cutting head 26 is at least two times greater than the second maximum outer diameter D2 of the shank 30. In some embodiments, the first maximum outer diameter DI may be between two times greater and five times greater than the second maximum outer diameter D2. In the illustrated embodiment, the first maximum outer diameter DI may be about three times greater than the second maximum outer diameter D2.

[0053] The shaft 34 extends from the shank 30 to the cutting head 26. As such, the shaft 34 may be understood to be a portion of the body 18 that extends between the portion of the body 18 that is inserted into and supported in the power tool, and where the body 18 begins to increase in diameter for the cutting head 26. The shaft 34 has a shaft length L3 and a third maximum outer diameter D3. The shaft length L3 is measured parallel to the central longitudinal axis AL The third maximum outer diameter D3 is measured perpendicular to the central longitudinal axis AL In the illustrated embodiment, the shaft length L3 may be more than half (i.e., 50%) of the total length LI of the drilling insert 10. As such, the shaft 34 extends, or spans, a majority of the total length LI of the body 18 of the drilling insert 10. In some embodiments, the shaft length L3 may be more than two-thirds (i.e., 66%) of the total length LI of the drilling insert 10. In further embodiments, the shaft length L3 may be more than three-quarters (i.e., 75%) of the total length LI of the drilling insert 10. In some embodiments, the shaft length L3 may be between 50% and 90% of the total length LI of the drilling insert 10.

[0054] As illustrated in FIG. 3, the groove 36 extends around the entire circumference of the body 18 and is formed between the shank 30 and the shaft 34. In other embodiments, the groove 36 may be formed in a portion of the shank 30 or the shaft 34. In further embodiments, the groove 36 may only partially extend along the circumference of the body 18 or may be one or more machined flat surface on the body 18. The groove 36 gives the7MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 body 18 a diameter D4 less than the diameters DI, D2, and D3 of the cutting head 26, the shank 30, and the shaft 34. respectively. The groove 36 is configured to receive and axially retain a sleeve retainer 40. In some embodiments, the body 18 may include other features to retain the sleeve retainer 40. For example, the body 18 may include a flange or one or more projections that engage and retain the sleeve retainer 40.

[0055] As illustrated in FIGS. 1 and 2, the sleeve 14 includes a sleeve body 58 and a plurality of sleeve lands 62 wrapped helically around the sleeve body 58. The sleeve 14 may be formed of a different material than the drilling insert 10. Alternatively, the sleeve 14 may be formed of the same material as the drilling insert 10. In the illustrated embodiment, the sleeve 14 is formed of a rigid material (e.g.. 4130 steel, 4340 steel, 6150H steel, 4140 steel, stainless steel, low carbon steel, anodized aluminum, or aluminum). In other embodiments, the sleeve 14 may be formed of a plastic material, a rubber, or another type of elastic material. The sleeve body 58 is configured to be mounted onto the body 18 of the drilling insert 10 such that the sleeve 14 radially surrounds the body 18 of the drilling insert 10. When mounted to the drilling insert 10, the sleeve 14 extends from the sleeve retainer 40 to the cutting head 26. That is, the sleeve 14 radially surrounds the shaft 34. As such, the sleeve 14 generally spans over the shaft length L2. The plurality of sleeve lands 62 defines a plurality of sleeve flutes 66. In other embodiments, the sleeve body 58 may only include a single land 62 and / or a single flute 66. The sleeve flutes 66 help transfer material away from the cutting head 26 during a cutting operation. At a forward end of the sleeve 14 that is adjacent to the cutting head 26, a forward portion of each of the sleeve lands 62 extends parallel to the central longitudinal axis Al of the drilling insert 10. Specifically, each of the lands 62 extends through a corresponding one of the flutes 42 defined by the lands 38 of the cutting head 26. The lands 62 help align the sleeve 14 on the body 18 and inhibit the sleeve 14 from rotating relative to the body 18. The sleeve 14, however, may shift or slide axially a small amount along the body 18 between the sleeve retainer 40 and the cutting head 26.

[0056] By providing the sleeve 14 separately from the drilling insert 10, the drilling insert 10 is able to transfer energy between the first end 18A and the second end 18B of the body 18 more efficiently. For example, when the drilling insert 10 is connected to a hammer drill, the hammer drill may impact the second end 18B of the body 18. The impacts travel or propagate through the body 18 to the first end 18A and. thereby, to a workpiece. Since the sleeve 14 is not fixed to the drilling insert 10, the impacts do not need to also travel through8MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 the mass of the sleeve 14. As such, as energy is transferred between the first end 18A and the second end 18B of the body 18, the energy does not travel through the plurality of sleeve lands 62 and the plurality of sleeve flutes 66. In addition, since the impacts travel along the drilling insert 10 as waves, and the body 18 is designed to minimize the number of changes in cross-sectional areas, the impacts do not become attenuated or distorted as they travel down the body 18. Therefore, the energy travels a more direct route, and thus a more efficient route, between the first end 18A and the second end 18B. Additionally, the plurality of sleeve lands 62 and the plurality of sleeve flutes 66 have an increased lifespan over typical drilling inserts. Specifically, the removal of energy transfer from the power tool through the plurality of sleeve lands 62 and the plurality of sleeve flutes 66 reduces the stress and risk of fracture for the plurality of sleeve lands 62 and the plurality of sleeve flutes 66.

[0057] FIG. 4 illustrates a method 400 of manufacturing a sleeve (such as the sleeve 14). Although the method 400 includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method 400 may include additional steps. Additionally, some of the steps may be performed simultaneously. FIGS. 5A-5C illustrate a stock 504 at the start of the method 400, a blank 508 formed during the method 400, and a sleeve 514 produced at the end of the method 400.

[0058] In step 410, the stock 504 is shaped to form the blank 508. In the embodiment illustrated in FIG. 5 A, the stock 504 is a hollow cylindrical tube. In other embodiments, the stock 504 may be a square tube, a hexagonal tube, an octagonal tube, or a polygonal-shaped tube. Shaping the stock 504 includes cutting the stock 504 to a desired length and applying a radial force to deform the stock 504. The radial force is applied to the stock 504 using a radial forging machine, where a plurality of hammers apply the radial force. The radial force of the hammers non-elastically deform the stock 504 to create a desired shape of the blank 508. As shown in FIG. 5B, the blank 508 is generallyshaped. In other embodiments, the blank 508 may be shaped like a five-point asterisk or a six-point asterisk. In some embodiments, the stock 504 is heated to a predetermined temperature (e.g., a forging temperature) before being placed in the radial forging machine.

[0059] In step 420. at least one flute 542 is formed in the blank 508 to produce the sleeve 514. To form the at least one flute 542, a first end 516A of the blank 508 is held stationary, while a torque is applied to a second end 516B of the blank 508. As the torque applied to the second end 516B increases, the blank 508 begins to twist and non-elastically deform. In9MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 other embodiments, torque may be applied to the first end 516A and the second end 516B may be held stationary. In some embodiments, torque may be applied to each end 516A, 516B in opposite directions. Torque is continuously applied until the flutes 542 are formed to a desired shape (e.g., helix angle). After the flutes 542 are formed, the blank 508 is considered the sleeve 514, as shown in FIG. 5C. The torque may be applied by a motor, an engine, or a lever. In some embodiments, the blank 508 is heated to a predetermined temperature (e.g., a forging temperature) before torque is applied to the second end 516B.

[0060] In some embodiments, the stock 504 may be shaped and twisted at the same time. For example, a twisting machine may simultaneously (or near simultaneously) shape and twist the stock 504 (i.e., the twisting machine by perform both step 410 and 420). Example twisting machines include those proposed by the Foshan Mingyi Machinery Co., Ltd, such as a pipe rolling machine, a tube twisting machine, and a tube threading machine.

[0061] In step 430. the sleeve 514 is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve 514 is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve 514. The axial force deforms the sleeve 514 to remove a curve or bend in the sleeve 514. In another embodiment, the sleeve 514 is passed through a tubing straightener device, including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve 514 to remove any curves or bends. In a further embodiment, the sleeve 514 is straightened by spot-heating portions of the sleeve 514.

[0062] In step 440, the sleeve 514 is hardened to improve the sleeve’s 514 durability. To harden the sleeve 514, the sleeve 514 is heated to a predetermined temperature (e.g., normalizing temperature) and is maintained at the predetermined temperature for a time period dependent on the thickness of the sleeve 514. In some embodiments, the time that the sleeve 514 is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve 514 is air-cooled back to room temperature. In other embodiments, the sleeve 514 may be cooled in oil, water, or other fluids. In other embodiments, the sleeve 514 may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes 542 may be hardened separately through carburizing. In still other embodiments, the sleeve 514 may be made of a material that hardens as the sleeve 514 is twisted (i.e., the sleeve 514 is work hardened).10MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0063] FIG. 6 illustrates an alternate method 600 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some of the steps may be performed simultaneously. FIGS. 7A-7E illustrate a stock 704 at the start of method 600, a blank 708 formed during the method 600, and a sleeve 714 produced once method 600 is completed.

[0064] In step 610, the stock 504 is shaped to form the blank 508. In the embodiment shown in FIG. 7A, the stock 704 is a square tube. In other embodiments, the stock 704 may be a cylindrical tube, a rectangular tube, a hexagonal tube, an octagonal tube, or a polygonal tube. Shaping the stock 704 involves cutting the stock 704 to a desired length and extruding the stock 706 through a die 720 using a hydraulic press or an arbor press. As the stock 704 is extruded through the die 720, the stock 704 is non-elastically deformed to form the blank 708 with a desired profile, as shown in FIGS. 7C-D. In some embodiments, forcing the stock 704 through the die 720 also twists the resulting blank 708 and forms a plurality of flutes 742. In further embodiments, the stock 704 is heated to a predetermined temperature (e.g., a forging temperature) before the hydraulic press applies an axial force to the stock 704.

[0065] At step 620, at least one flute 742 is formed on the blank 708 to produce the sleeve 714 (FIG. 7E). To form the at least one flute 742 on the blank 708, a first end of the blank 708 is held stationary while a torque is applied to a second end of the blank 708. In other embodiments, torque may be applied to the first end, and the second end may be held stationary’. In still other embodiments, torque may be applied to both ends of the blank 708 in opposite directions. As the torque applied to the second end increases, the blank 708 begins to twist and non-elastically deform. Torque is continuously applied until the flutes 742 are formed to a desired shape (e.g., helix angle). After the flutes 742 are formed, the blank 708 is considered the sleeve 714, as shown in FIG. 7E. The torque may be applied by a motor, an engine, or a lever. In some embodiments, the blank 708 is heated to a predetermined temperature (e.g., a forging temperature) before torque is applied to the second end.

[0066] In step 630. the sleeve 714 is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve 714 is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve 714. The axial force deforms the sleeve 714 to remove a curve or bend in the sleeve 714. In another embodiment, the sleeve 714 is passed through a tubing straightener11MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 device, including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve 714 to remove any curves or bends. In a further embodiment, the sleeve 714 is straightened by spot-heating portions of the sleeve 714.

[0067] In step 640, the sleeve 714 is hardened to improve the sleeve’s 714 durability. To harden the sleeve 714, the sleeve 714 is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the normalizing temperature for a time period dependent on the thickness of the sleeve 714. In some embodiments, the time that the sleeve 714 is maintained at the normalizing temperature is 1 hour per 1 inch of thickness. Next, the sleeve 714 is air-cooled back to room temperature. In other embodiments, the sleeve 714 may be cooled in oil. water, or other fluids. In other embodiments, the sleeve 714 may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes 742 may be hardened separately through carburizing. In still other embodiments, the sleeve 714 may be made of a material that hardens as the sleeve 714 is twisted (i. e.. the sleeve 714 is work hardened).

[0068] FIG. 8 illustrates an alternate method 800 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some steps may be performed simultaneously. FIG. 9 illustrates a sleeve 914 produced once the method 800 is completed.

[0069] In step 810. a stock (not shown) is shaped to form a blank (not shown). The stock is a square tube. In other embodiments, the stock may be a rectangular tube, a hexagonal tube, an octagonal tube, or a polygonal tube. Shaping the stock to form the blank involves cutting the stock to a desired length.

[0070] In step 820. at least one flute 942 is formed in the blank to produce the sleeve 914. To form the flutes 942, a first end of the blank is held stationary, while a torque is applied to a second end of the stock. In another embodiment, the second end of the blank may be held stationary, while a torque is applied to the second end. In still other embodiments, torque may be applied to both ends of the blank in opposite directions. As the torque applied to the second end increases, the blank begins to twist and non-elastically deform. Torque is continuously applied until the flutes 942 are formed into a desired shape (e.g., helix angle). After the flutes 942 are formed, the blank is considered the sleeve 914, as12MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 shown in FIG. 9. The torque may be applied by a motor, an engine, or a lever. In some embodiments, the stock is heated to a predetermined temperature (e.g., a forging temperature) before torque is applied to the second end.

[0071] In step 830, the sleeve 914 is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve 914 is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve 914. The axial force deforms the sleeve 914 to remove a curve or bend in the sleeve 914. In another embodiment, the sleeve 914 is passed through a tubing straightener device, including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve 914 to remove any curves or bends. In a further embodiment, the sleeve 914 is straightened by spot heating portions of the sleeve 914.

[0072] In step 840, the sleeve 914 is hardened to improve the sleeve's 914 durability. To harden the sleeve 914, the sleeve 914 is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the predetermined temperature for a time period dependent on the thickness of the sleeve 914. In some embodiments, the time that the sleeve 914 is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve 914 is air-cooled back to room temperature. In further embodiments, the sleeve 914 may be cooled in oil, water, or other fluids. In further embodiments, the flutes 942 may be hardened separately through carburizing. In still other embodiments, the sleeve 914 may be made of a material that hardens as the sleeve 914 is twisted (i.e., the sleeve 914 is work hardened).

[0073] FIG. 10 illustrates an alternate method 1000 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some of the steps may be performed simultaneously. FIGS. 1 1 A-l ID illustrate a stock 1104 to be used in the method 1000, a partially formed blank 1108 formed during the method 1000, a complete blank 1112 formed during the method 1000, and a sleeve 1114 produced once the method 1000 has been completed.

[0074] In step 1010, the stock 1104 is shaped to form the complete blank 1112. The stock 1104 is a solid rod with a circular cross-section of a desired material. In other13MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 embodiments, the stock 1104 may have a square cross-section, a hexagonal cross-section, an octagonal cross-section, or a polygonal cross-section. Shaping the stock 1104 to form the complete blank 1 112 first involves cutting the stock 1 104 to a desired length to fit on the shaft 34 of the drilling insert 10. Next, a plurality of straight flutes 1122 is machined into the blank using a CNC machine, a milling machine, or a CNC lathe to create the partially formed blank 1108, as shown in FIG. 1 IB. The straight flutes 1122 extend axially along the blank 1108 parallel to a longitudinal axis of the blank 1108. Then, a core of the partially formed blank 1108 is removed using a gun drilling machine. In other embodiments, the core of the partially formed blank 1108 may be removed using a single tube system (STS) drilling machine. Once the core is removed, the partially formed blank 1108 is considered the complete blank 1112, as shown in FIG. 11C.

[0075] At step 1020, at least one flute 1142 is formed on the complete blank 1112 to produce the sleeve 1114. To form the flutes 1142, a first end of the complete blank 1112 is held stationary, while a torque is applied to a second end of the complete blank 1112. In other embodiments, the second end of the complete blank 1112 may be held stationary while a torque is applied to a second end. In still other embodiments, torque may be applied to both ends of the blank 1112 in opposite directions. As the torque applied to the second end increases, the complete blank 1112 begins to twist and non-elastically deform. Torque is continuously applied until the flutes 1142 are formed into a desired shape (e.g.. helix angle). After the flutes 1142 are formed, the complete blank 1112 is considered the sleeve 1114, as show n in FIG. 1 ID. The torque may be applied by a motor, an engine, or a lever. In some embodiments, the complete blank 1112 is heated to a predetermined temperature (e.g., a forging temperature) before torque is applied to the second end.

[0076] In step 1030, the sleeve 1114 is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve 1114 is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve 1114. The axial force deforms the sleeve 11 14 to remove a curve or bend in the sleeve 1114. In another embodiment, the sleeve 1114 is passed through a tubing straightener device, including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve 1114 to remove any curves or bends. In a further embodiment, the sleeve 1114 is straightened by spot heating portions of the sleeve 1114.14MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0077] In step 1040, the sleeve 1114 is hardened to improve the sleeve's 1114 durability’. To harden the sleeve 1114, the sleeve 1114 is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the predetermined temperature for a time period dependent on the thickness of the sleeve 1114. In some embodiments, the time that the sleeve 1114 is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve 1114 is air-cooled back to room temperature. In other embodiments, the sleeve 1114 may be cooled in oil, water, or other fluids. In other embodiments, the sleeve 11 14 may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes 1142 may be hardened separately through carburizing. In still other embodiments, the sleeve 1114 may be made of a material that hardens as the sleeve 1114 is twisted (i. e.. the sleeve 1114 is work hardened).

[0078] FIG. 12 illustrates an alternate method 1200 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some of the steps may be performed simultaneously. FIGS. 13A-13D illustrate a plurality of exemplary blanks 1308A, 1308B, 1308C formed during the method 1200 and a sleeve 1314B produced once the method 1200 is completed.

[0079] In step 1210, the stock (not shown) is shaped to fit on the shaft 34 of the drilling insert 10 and to form one of the blank 1308A (FIG. 13A). the blank 1308B (FIG. 13B) or the blank 1308C (FIG. 13C). The stock is shaped through a metal extrusion process, where the stock is pressed through a die to be deformed. In some embodiments, the stock is initially heated before being pressed through the die. Once the stock is pressed through the die, the blank 1308A is formed.

[0080] To form the blank 1308B (FIG. 13B), the stock is shaped through closed die forging, where the stock is heated to a predetermined temperature (e.g., a forging temperature) and is compressed within a die to produce the blank 1308B. In some embodiments, the stock is shaped using open die forging or is hand forged. In some embodiments, the stock may have to be cut to a desired size and machined after the forging procedure to form dimension sensitive features. In further embodiments, the stock may be15MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 shaped to from the blank 1308B through a metal extrusion process similar to that used to form the blank 1308A.

[0081] To form the blank 1308C from the stock, the forging process used to form the blank 1308B is completed twice to form two blanks 1308B. Next, the two blanks 1308B are joined by tack welding to form the blank 1308C, as shown in FIG. 13C. In other embodiments, the two blanks 1308B may be joined through TIG welding, MIG welding, or laser welding.

[0082] At step 1220, at least one flute 1342B is formed on the blank 1308B to produce the sleeve 1314B. To form the flutes 1342B, a first end of the blank 1308B is held stationary, while a torque is applied to a second end of the blank 1308B. In another embodiment, the second end is held stationary', while a torque is applied to the first end. In still other embodiments, torque may be applied to both ends of the blank 1308B in opposite directions. As the torque applied to the second end increases, the blank 1308B begins to twist and non- elastically deform. Torque is continuously applied until the flutes 1342B are formed into a desired shape (e.g., helix angle). After the flutes 1342B are formed, the blank 1308B is considered the sleeve 1314B, as shown in FIG. 13D. The torque may be applied by a motor, an engine, or a lever. In some embodiments, the blank 1308B is heated to a predetermined temperature (e.g., a forging temperature) before torque is applied to the second end. The procedure of step 1220 remains the same even, if in step 1210, the stock is shaped into the blank 1308A or the blank 1308C.

[0083] In a step 1230, the sleeve 1314B is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve 1314B is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve 1314B. The axial force deforms the sleeve 1314B to remove a curve or bend in the sleeve 1314B. In another embodiment, the sleeve 1314B is passed through a tubing straightener device including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve 1314B to remove any curves or bends. In a further embodiment, the sleeve 1314B is straightened by spot heating portions of the sleeve 1314B. The same procedure of step 1230 applies to a sleeve formed from either the blank 1308A or 1308C.16MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0084] In a step 1240, the sleeve 1314B is hardened to improve the sleeve’s 1314B durability’. To harden the sleeve 1314B. the sleeve 1314B is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the predetermined temperature for a time period dependent on the thickness of the sleeve 1314B. In some embodiments, the time that the sleeve 1314B is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve 1314B is air-cooled back to room temperature. In other embodiments, the sleeve 1314B may be cooled in oil, water, or other fluids. In other embodiments, the sleeve 1314B may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes 1342 may be hardened separately through carburizing. In still other embodiments, the sleeve 1314B may be made of a material that hardens as the sleeve 1314B is twisted (i.e., the sleeve 1314B is work hardened). The same procedure of step 1240 applies to a sleeve formed from either the blank 1308A or 1308C.

[0085] FIG. 14 illustrates an alternate method 1400 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some of the steps may be performed simultaneously. FIGS. 15A-15C illustrate a stock 1504 at the start of the method 1400, a partially formed blank 1508 formed during the method 1400. and a complete blank 1512 formed during the method 1400.

[0086] In step 1410, the stock 1504 is shaped to form the complete blank 1512. As shown in FIG. 15 A, the stock 1504 is a sheet of a rigid material (e.g.. steel, stainless steel, or aluminum). To shape the stock 1504, the stock 1504 is stamped and bent to form a complete blank 1512. The stock 1504 is initially inserted into a die coupled to a stamping press. Then, the stamping press lowers the die onto the stock 1504 and compresses the stock 1504. Next, the stamping press releases the stock 1504 from the die. and the stock 1504 is non-elastically deformed to create a partially formed blank 1508 (FIG. 15B). In other embodiments, different cross sections may be formed using different dies. Lastly, the partially formed blank 1508 is inserted into a sheet metal brake to fold the partially formed blank 1508 to form the complete blank 1512 (FIG. 15C). In some embodiments, the non-folded edge of the complete blank 1512 is welded to maintain the bent shape. In another embodiment, the stock 1504 may be a rectangular stock material, and the partially formed blank 1508 may be17MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 formed through a metal extrusion process. Once extruded, the partially formed blank 1508 may be folded to form the complete blank 1512.

[0087] At step 1420, at least one flute (not shown) is formed in the complete blank 1512 to produce a sleeve (not shown). To form the flutes, a first end of the complete blank 1512 is held stationary, while a torque is applied to a second end of the complete blank 1512. In another embodiment, the second end of the complete blank 1512 is held stationary while a torque is applied to the first end. In still other embodiments, torque is applied to both ends of the blank 1512 in opposite directions. As the torque applied to the second end increases, the complete blank 1512 begins to twist. Torque is continuously applied until the flutes are formed into a desired shape (e.g., helix angle). After the flutes are formed, the complete blank 1512 is considered the sleeve. The torque may be applied by a motor, an engine, or a lever. In some embodiments, the complete blank 1512 is heated to a predetermined temperature (e.g., a forging temperature) before torque is applied to the second end.

[0088] In step 1430, the sleeve is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve. The axial force deforms the sleeve to remove a curve or bend in the sleeve. In another embodiment, the sleeve is passed through a tubing straightener device including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve to remove any curves or bends. In a further embodiment, the sleeve is straightened by spotheating portions of the sleeve.

[0089] In step 1440, the sleeve is hardened to improve the sleeve’s durability. To harden the sleeve, the sleeve is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the predetermined temperature for a time period dependent on the thickness of the sleeve. In some embodiments, the time that the sleeve is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve is aircooled back to room temperature. In other embodiments, the sleeve may be cooled in oil, water, or other fluids. In other embodiments, the sleeve may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes may be hardened separately through carburizing. In still other embodiments, the sleeve may be made of a material that hardens as the sleeve is tw isted (i.e., the sleeve is work hardened).18MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0090] FIG. 16 illustrates an alternate method 1 00 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some of the steps may be performed simultaneously. FIG. 17 illustrates a sleeve 1714 produced once the method 1600 is completed.

[0091] In step 1610, a stock is shaped to form a first blank 1712A and a second blank 1712B. Shaping the stock involves cutting the stock to a desired length to fit on the shaft 34 of the drilling insert 10.

[0092] In step 1620, a portion of a flute 1742 is formed in the first blank 1712A and the second blank 1712B. Then, the first blank 1712A and the second blank 1712B are joined to form the sleeve 1714, and the portions of the flutes 1742 are also joined to form at least one complete flute 1742 on the sleeve 1714. The portions of the flute 1742 on the first and second blanks 1712A, 1712B are formed through machining using a CNC, a milling machine, a CNC lathe, or a combination of the preceding. Then, the first and second blanks 1712A, 1712B are aligned to match the portions of the sleeve flutes 1742 on each. Once aligned, an interface between the first blanks 1712A and the second blank 1712B is welded using laser welding. In other embodiments, the interface may be welded using MIG welding, TIG welding, or brazing. Once the interface is welded, the first blank 1712A and the second blank 1712B are fixedly coupled and form the sleeve 1714.

[0093] In step 1630, the sleeve 1714 is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve 1714 is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve 1714. The axial force deforms the sleeve 1714 to remove a curve or bend in the sleeve 1714. In another embodiment, the sleeve 1714 is passed through a tubing straightener device, including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve 1714 to remove any curves or bends. In a further embodiment, the sleeve 1714 is straightened by spot heating portions of the sleeve 1714.

[0094] In step 1640, the sleeve 1714 is hardened to improve the sleeve’s 1714 durability. To harden, the sleeve 1714 is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the predetermined temperature for a time period dependent19MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 on the thickness of the sleeve 1714. In some embodiments, the time that the sleeve 1714 is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve 1714 is air-cooled back to room temperature. In other embodiments, the sleeve 1714 may be cooled in oil, water, or other fluids. In other embodiments, the sleeve 1714 may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes 1742 may be hardened separately through carburizing. In still other embodiments, the sleeve 1714 may be made of a material that hardens as the sleeve 1714 is twisted (i.e., the sleeve 1714 is work hardened).

[0095] FIG. 18 illustrates an alternate method 1800 of manufacturing a sleeve (such as the sleeve 14). Although the method includes particular steps, not all of the steps need to be performed or need to be performed in the order presented. In some embodiments, the method may include additional steps. Additionally, some of the steps may be performed simultaneously.

[0096] In step 1810, a stock (not shown) is shaped to form a blank (not shown). Shaping the stock involves cutting the stock to a desired length to fit on the shaft 34 of the drilling insert 10 and removing a core of the stock. The core of the stock is removed through a gun drilling machine or a single tube system (STS) drilling machine.

[0097] In a step 1820, at least one flute (not shown) is formed on the blank to produce a sleeve (not shown). The at least one flute is formed on the blank through machining using a CNC, a milling machine, a CNC lathe, or a combination of the preceding.

[0098] In a step 1830, the sleeve is straightened to ensure a proper fit onto the shaft 34 of the drilling insert 10 and remove any wobble when rotated about a longitudinal axis. The sleeve is placed into a V-block, and a hydraulic press applies an axial force to a portion of the sleeve. The axial force deforms the sleeve to remove a curve or bend in the sleeve. In another embodiment, the sleeve is passed through a tubing straightener device, including a plurality of V-shaped rollers. The plurality of V-shaped rollers compresses the sleeve to remove any curves or bends. In a further embodiment, the sleeve is straightened by spot heating portions of the sleeve.

[0099] In a step 1840, the sleeve is hardened to improve the sleeve's durability. To harden, the sleeve is heated to a predetermined temperature (e.g., a normalizing temperature) and is maintained at the predetermined temperature for a time period dependent on the20MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01 thickness of the sleeve. In some embodiments, the time that the sleeve is maintained at the predetermined temperature is 1 hour per 1 inch of thickness. Next, the sleeve is air-cooled back to room temperature. In other embodiments, the sleeve may be cooled in oil, water, or other fluids. In other embodiments, the sleeve may be hardened through induction hardening, flame hardening, diffusion hardening, or carburizing. In further embodiments, the flutes may be hardened separately through carburizing. In still other embodiments, the sleeve may be made of a material that hardens as the sleeve is twisted (i.e., the sleeve is work hardened).

[0100] FIG. 19 illustrates the drilling insert 10 including another sleeve 2014. Similar to the sleeve 14 shown in FIGS. 1 and 2, the illustrated sleeve 2014 includes a sleeve body 2058 and a plurality of sleeve lands 2062 wrapped helically around the sleeve body 2058. The sleeve 2014 may be formed of a different material than the drilling insert 2010.Alternatively, the sleeve 2014 may be formed of the same material as the drilling insert 2010. In the illustrated embodiment, the sleeve 2014 is formed of a rigid material (e.g., 4130 steel, 4340 steel, 6150H steel, 4140 steel, stainless steel, low carbon steel, anodized aluminum, or aluminum). In other embodiments, the sleeve 2014 may be formed of a plastic material, a rubber, or another type of elastic material. The sleeve body 2058 is configured to be mounted onto the body 18 of the drilling insert 10 such that the sleeve 2014 radially surrounds the body 18 of the drilling insert 10. When mounted to the drilling insert 10, the sleeve 2014 extends from the sleeve retainer 40 (FIG. 2) to the cutting head 26. As such, the sleeve 2014 generally spans over the shaft length L3 (FIG. 3). The plurality of sleeve lands 2062 defines a plurality of sleeve flutes 2066. In other embodiments, the sleeve body 2058 may only include a single land 2062 and / or a single flute 2066. The sleeve flutes 2066 help transfer material away from the cutting head 26 during a cutting operation.

[0101] The illustrated sleeve 2014 is formed of multiple segments 2070 or sections. Each segment 2070 is a discrete component. In the illustrated embodiment, the sleeve 2014 is formed of three segments 2070. In other embodiments, the sleeve 2014 may be formed of fewer than three segments 2070 (e.g., two segments 2070) or more than three segments 2070 (e.g., four segments 2070, five segments 2070, etc.). The number of segments 2070 may be determined by the shaft length L3 (FIG. 3). That is, the segments 2070 may be used with drilling inserts of different lengths. In the illustrated embodiment, each segment 2070 is generally the same length. For example, each of the illustrated segments 2070 is generally 1 / 3 of a total length of the sleeve 2014 (or the shaft length L3), but may alternatively be 1 / 2,21MBF\066042\ 1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO011 / 4, etc. of the total length of the sleeve 2014 depending on the number of segments 2070. In other embodiments, the segments 2070 may have different lengths relative to each other. For example, one segment 2070 may be 1 / 2 of the total length of the sleeve 2014, while the other two segments 2070 may each be 1 / 4 of the total length of the sleeve 2014.

[0102] As shown in FIGS. 20 and 21, each segment 2070 has a first end 2074 and a second end 2078. The first and second ends 2074, 2078 each have a coupling portion 2082 configured to interface with an adjacent segment 2070. The illustrated coupling portions 2082 each include two flats 2086 that engage two flats 2086 of an adjacent segment 2070. In other embodiments, the coupling portions 2082 may have other configurations. The coupling portions 2082 may interface with each other by abutting each other. As such, rotation of one segment 2070 is transferred to an adjacent segment 2070 through the coupling portions 2082. Alternatively, the coupling portions 2082 may be secured together by welding, adhesives, fasteners, or the like. When coupled together, the segments 2070 form the sleeve body 2058, the sleeve lands 2062, and the sleeve flutes 2066.

[0103] Referring to FIGS. 22 and 23, in another embodiment, a sleeve 2114 for the drilling insert 10 may be formed from an angle iron 2118. The angle iron 2118 may also be referred to as angle stock or metal angle stock. The angle iron 2118 is a single, continuous piece of material including a first leg 2222 and a second leg 2226. The legs 2222, 2226 extend perpendicular to each other. Although referred to as iron, the angle iron 2118 may be formed from metal (e.g., steel, aluminum, etc.), plastic, or the like, similar to the sleeves described above.

[0104] As shown in FIG. 23, the angle iron 2118 is twisted about its length to form a helical sleeve body 2158. Edges of the angle iron 2118 and a junction between the legs 2222, 2226 of the angle iron 2118 form a plurality of sleeve lands 2162 that wrap helically about the sleeve body 2158. When mounted to the drilling insert 10, the sleeve 2114 extends from the sleeve retainer 40 (FIG. 2) to the cutting head 26. As such, the sleeve 21 14 generally spans over the shaft length L3 (FIG. 3). The plurality of sleeve lands 2162 defines a plurality of sleeve flutes 2166. In the illustrated embodiment, the sleeve 2114 includes three sleeve lands 2162 defining two sleeve flutes 2166. In other embodiments, the sleeve body 2058 may only include a single land 2162 and / or a single flute 2166. The sleeve flutes 2166 help transfer material away from the cutting head 26 during a cutting operation.22MBF\066042\ 1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WO01

[0105] FIGS. 24 and 25 illustrate another sleeve 2214 formed from the angle iron 2118 (FIG. 22). In the illustrated embodiment, the sleeve 2214 is formed from two angle irons 2118. Edges of the angle irons 2218 are positioned adjacent or in contact with each other to form an enclosed sleeve around the drilling insert 10. In some embodiments, the angle irons 2218 may be secured (e.g., welded, brazed, glued, fastened, etc.) together. The angle irons 2118 are twisted about their lengths to form a helical sleeve body 2258. The angle irons 2118 may be twisted before or after being coupled together. Edges of the angle irons 21 18 and junctions between the legs 2222, 2226 of the angle irons 2118 form a plurality of sleeve lands 2262 that wrap helically about the sleeve body 2258. When mounted to the drilling insert 10, the sleeve 2214 extends from the sleeve retainer 40 (FIG. 2) to the cutting head 26. As such, the sleeve 2214 generally spans over the shaft length L3 (FIG. 3). The plurality of sleeve lands 2262 defines a plurality of sleeve flutes 2266. In the illustrated embodiment, the sleeve 2214 includes four sleeve lands 2262 defining four sleeve flutes 2266. The sleeve flutes 2266 help transfer material away from the cutting head 26 during a cutting operation.

[0106] In some embodiments, the angle iron 2118, and thereby the sleeves 2114, 2214, may be segmented, similar to the sleeve 2014 described above.

[0107] A sleeve (such as the sleeve 14, the sleeve 2014, the sleeve 2114, or the sleeve 2214) formed using one of the preceding methods 400, 600, 800, 1000, 1200, 1400, 1600, or 1800 may be coupled to the drilling insert 10 to perform a drilling operation. To perform a drilling operation in rebar, brick, block, and other similar material, the drilling insert 10 is fully assembled before the sleeve 14, 2014 is mounted to the drilling insert 10. To assemble the drilling insert 10, the cutting insert 22 is installed onto the cutting head 26 of the drilling insert 10. In other embodiments, various cutting inserts are installed depending on the material to be drilled. Next, the second end of the drilling insert 10 is slid through the sleeve 14, 2014, 2114, 2214 until an end of the sleeve 14, 2014, 2114, 2214 is adjacent to or abuts the cutting head 26. Then, the sleeve retainer 40 is installed onto the groove 36 of the drilling insert 10, which limits the removal of the sleeve 14, 2014, 2114, 2214 from the body 18 of the drilling insert 10. Finally, the shank 30 is coupled to a desired power tool to provide torque to the drilling insert 10 and perform the drilling operation.

[0108] Various features and advantages of the invention are set forth in the following claims.23MBF\066042\ 1962\41309168.v2-9 / 10 / 25

Claims

Attorney Docket No. 066042-1962 -WOOlCLAIMSWhat is claimed is:

1. A method of manufacturing a sleeve for a drilling insert, the method comprising: shaping a stock to form a blank; and forming a flute in the blank to produce a sleeve configured to be mounted on a shaft of the drilling insert.

2. The method of claim 1, further comprising straightening the sleeve.

3. The method of claim 1, further comprising hardening the sleeve.

4. The method of claim 3, wherein hardening the sleeve includes: heating the sleeve to a temperature, maintaining the sleeve at the temperature for a period of time, and cooling the sleeve from the temperature to room temperature.

5. The method of claim 3, wherein hardening the sleeve includes work hardening the sleeve as the sleeve is twisted.

6. The method of claim 1, wherein forming the flute in the blank to produce the sleeve includes applying a torque to a first end of the blank and maintaining a second end of the blank stationary to non-elastically deform the blank.

7. The method of claim 1, w herein forming the flute in the blank to produce the sleeve includes applying torque to both a first end and a second end of the blank to non-elastically deform the blank.

8. The method of claim 1, wherein forming the flute in the blank to produce the sleeve includes machining the flute into the blank.

9. The method of claim 1 , wherein shaping the stock to form the blank and forming the flute in the blank to produce the sleeve includes simultaneously shaping the stock and forming the flute with a twisting machine.24MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WOOl10. The method of claim 1, wherein shaping the stock to form the blank includes deforming the stock by applying a radial force using a radial forge.

11. The method of claim 1, wherein shaping the stock to form the blank includes deforming the stock by applying axial force to extrude the stock through a die.

12. The method of claim 1, wherein shaping the stock to form the blank includes machining the stock to form the blank.

13. The method of claim 1, wherein shaping the stock to form the blank includes deforming the stock through forging.

14. The method of claim 1, wherein shaping the stock to form the blank includes stamping the stock and bending the stock.

15. The method of claim 1, wherein shaping the stock to form the blank includes: machining the stock to form two partially formed blanks, and coupling the two partially formed blanks together to form the blank.

16. The method of claim 15. wherein coupling the two partially formed blanks together includes welding the two partially formed blanks together to form the blank.

17. A drill bit assembly comprising: a drilling insert including a body having a first end and a second end opposite the first end, the body including a cutting head positioned at the first end, a shank positioned at the second end, the shank configured to be coupled to a tool, and a shaft extending between the cutting head and the shank; and a sleeve formed by the method of claim 1, the sleeve mounted on the body to radially surround the shaft.

18. A drill bit assembly comprising:25MBF\066042\1962\41309168.v2-9 / 10 / 25Attorney Docket No. 066042-1962 -WOOl a drilling insert including a body having a first end and a second end opposite the first end, the body including a cutting head positioned at the first end, a shank positioned at the second end, the shank configured to be coupled to a tool, and a shaft extending between the cutting head and the shank; and a sleeve mounted on the body to radially surround the shaft, the sleeve including multiple segments that are secured together to form a sleeve body and a plurality of sleeve lands wrapped helically around the sleeve body to define a flute.

19. The drill bit assembly of claim 18. wherein each segment of the multiple segments has a coupling portion with a flat, and wherein the flat of one segment engages the flat of an adjacent segment.

20. A drill bit assembly comprising: a drilling insert including a body having a first end and a second end opposite the first end, the body including a cutting head positioned at the first end, a shank positioned at the second end, the shank configured to be coupled to a tool, and a shaft extending between the cutting head and the shank; and a sleeve mounted on the body to radially surround the shaft, the sleeve including an angle iron that is twisted about its length to form a sleeve body with a plurality of sleeve lands that wrap helically about the sleeve body to define a flute.

21. The drill bit assembly of claim 20, wherein the angle iron is a first angle iron, and wherein the sleeve includes a second angle iron that is secured to the first angle iron and twisted about its length with the first angle iron to form the sleeve body with the plurality’ of sleeve lands.26MBF\066042\1962\41309168.v2-9 / 10 / 25

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