Products

Products

Meet The

Toughest Diamond Mining Tools You'll Ever Use

US Synthetic Mining is the leader in high-density ceramic roof bolt mining tools-focused on improving the production and safety of today’s underground mining operations. The engineering expertise and unique diamond technology built into every product makes US Synthetic Mining tools the longest lasting and most technically advanced products on the market. US Synthetic Mining offers a proven track record of performance-delivering unmatched durability and toughness from the easiest to the most difficult roof-bolting conditions.

Diamond Sintering

The extreme hardness, wear resistance, and thermal conductivity of diamond make it an ideal cutting tool material. However, individual diamond crystals cleave quite easily when struck parallel to certain planes (the process used to facet diamond gemstones takes advantage of these relatively weak planes). As a result, individual diamond crystals do not make good cutting tools—unless they are meticulously oriented.

Diamond sintering overcomes the problem of weak planes in diamond gemstones by bonding a mass of small diamond particles onto a larger, coherent structure. Sintered diamond provides greater toughness and durability than single crystals because the individual crystals in a sintered body are randomly oriented. This prevents cracks from propagating along the weak planes where traditional diamond crystals cleave most easily. Sintered diamonds also provide more uniform wear than a single crystal, while maintaining similar thermal conductivity and hardness properties. All of these factors combine to make sintered diamond the preferred material for cutting rock.

At US Synthetic, the sintering process begins with premium grade diamond crystals. These crystals are sintered together at temperatures of approximately 1400°C and pressures of around 60 kbar in the presence of a liquid metal catalyst. Typically, the diamond is bonded to a tungsten carbide substrate during the same high-temperature, high-pressure process. This sintered diamond and tungsten carbide composite is known in the industry as a polycrystalline diamond cutter (PDC).

Diamond Finishing

The extreme hardness of diamonds presents obvious machining and finishing challenges. In typical machining situations, the finishing tool is harder than the work piece. With diamond inserts, this isn’t possible, since diamond is the hardest known substance. This makes machining diamond analogous to cutting through a wooden beam with a wooden saw. As a result, US Synthetic uses millions of carats of industrial diamond each year to machine and finish PDCs to their final dimensions. Over the years, we have developed specialized techniques and machines for lapping, grinding, polishing, brazing, and cutting PDC inserts. These techniques make it possible for us to finish PDCs to exacting specifications, despite the inherent challenges of machining sintered diamond.

Wasp Bit

The US Synthetic Mining Wasp bit brings together the very latest in diamond drilling materials and innovative, new bit design to offer the longest lasting, most durable dry roof bolting drill bit in the world.

*results vary by location

FEATURES AND BENEFITS

  • Drills up to 300 times longer
  • Increases tonnage and production
  • Penetrates hard rock faster
  • Reduces thrust requirements by approximately 75%, increasing drill steel life and eliminating extensive wear on equipment
  • Reduces respirable dust by approximately 78%
  • Significantly reduces equipment downtime by eliminating the ongoing need to change out worn/broken carbide

Viper Bit

The US Synthetic Mining Viper bit brings superior diamond drilling materials and innovative, bit design to offer long-lasting, durable dry roof bolting drill bit.

FEATURES AND BENEFITS

  • Drills 50 – 200 times longer
  • Increases tonnage and production
  • Penetrates hard rock faster
  • Reduces thrust requirements by 50%, increasing drill steel life and eliminating extensive wear on equipment
  • Reduces respirable dust by approximately 78%
  • Significantly reduces equipment downtime by eliminating the ongoing need to change out worn/broken carbide

CERAMIC DUST HOGS: POLYCRYSTALLINE DIAMOND (PCD) ROOF DRILL BITS

DRY DRILLING

US Synthetic diamond viper and Wasp bits simply outlast all other product on the market, significantly outperforming tungsten carbide dust hogs.

INCREASE TONNAGE AND PRODUCTION

  • Drill more than 100-300 times longer
  • Penetrate hard rock faster
  • Reduce thrust requirements by 50% to increase drill steel life (6x) and to eliminate extensive wear on equipment
  • Reduce respirable dust by approximately 78% and noise levels by approximately 10 decibels
  • Significantly reduce equipment downtime by eliminating the ongoing need to change out and replace worn or broken carbide dust hogs

“A 200 to 600 times increase in bit life should reduce injuries occurring during bit replacement and other activities related to roof-bolting operation. (Special Report, Breakthrough in Roof-bolt Drill Bit Technology, U.S. Bureau of Mines).”

STOP WAITING-INCREASE YOUR TONNAGE

DIAMOND TIP WET DRILLING BITS

IMPROVED DIAMOND BITS

US Synthetic Ceramic (Diamond) Wet Bits are new and revolutionary for improving the efficiency and mining costs associated with drilling.

BENEFITS OF DIAMOND BITS:

  • Outperform carbide wet drilling by 100 to 300 times longer
  • Increase rate of penetration
  • Replace percussion drilling
  • Reduce drill maintenance
  • Lower drill steel cost by reducing thrust requirements and extensive wear
  • Significantly reduce equipment downtime by eliminating the ongoing
    need to change out and replace worn
    or broken carbide wet bits

“The cutting edge of a PDC bit remains relatively sharp throughout its life. (Optimum Thrust, Cutting Speed, and Water Pressure for Tungsten Carbide and Polycrystalline Diamond Compact Roof-Bolt Drill Bits, U.S. Bureau of Mines, 1995.)”

DIAMOND DRILL REAMERS

REAMERS AND BIT SEATS

The advanced technology in US Synthetic reamers and bit seats substantially decrease bolting time-allowing operators to maintain continuous production output.

US SYNTHETIC BITS:

  • Decrease bolting time
  • Maintain the gauge of the hole
  • Adapts to most round or hex tubular drill steel extension rods
  • Eliminate hole rifling and irregularities
  • Increase durability and wear resistance
  • Fewer stuck drill steel to fight
  • Easier and faster to install resin cartridges, standard bolts and cable bolts

“Miners were quick to accept PDC bits, since they reduced by more than 50 times the necessity of replacing worn out bits. (Special Report, Breakthrough in Roof-bolt Drill Bit Technology, U.S. Bureau of Mines.)”

HIGH-GRADE INDUSTRIAL DRILL STEEL: ANTI-NOISE / THREADED HEX DRILL STEEL

HIGH-SPEED DRILL STEEL

US Synthetic Mining High-Grade Industrial Drill Steel is designed for exceptional strength using high-grade alloy.

INCREASE DURABILITY AND LOWER MINING COST:

  • Remains straight under high thrust conditions
  • Lasts approximately 20-times longer than traditional drill steel
  • Delivers excellent fatigue strength to attain longer life
  • Assembled with noise dampening materials
  • Incorporated into a universal, easy-to-use shank
  • Adapts to most round or hex tubular drill steel extension rods

“…by reducing the number of operations a worker must perform, PDC bits may significantly reduce the number of non-fatal accidents resulting in lost-time injuries, associated with roof-drilling operations. (Special Report, Breakthrough in Roof-bolt Drill Bit Technology, U.S. Bureau of Mines).”

CUSTOM DESIGNED, EASY-TO-USE TOOLING

THREADED CUSTOM MADE COUPLINGS

US Synthetic Mining is dedicated to supporting our customers with easy-to-use couplers and custom-designed tooling.

DELIVERED QUALITY TO SUPPORT CONSISTENT PRODUCTION:

  • Standard couplings that adapt to most round or hex tubular drill steel
  • Unique threaded couplings for secure connections
  • Highest quality materials
  • Custom-designed applications
  • Dedicated engineering support

“PDC bits were operating at one-half the thrust and rotational speed required by the WC-Co bits. (Special Report, Breakthrough in Roof-bolt Drill Bit Technology, U.S. Bureau of Mines).”