ANALYTICAL AND EXPERIMENTAL STUDY ON PDC DRILL BITS QUALITY
Under geological extreme conditions, polycrystalline diamond compact bits (PDC) are a relevant choice because of their interesting drilling performances. In this way, the quality of innovating PDC bits materials has to be determined with accuracy by measuring cutting efficiency and wear rate, both related to the overall mechanical properties. A lathe-type test device was used to proceed to the first experiments. During these tests, cutters have been worn over an abrasion length greater than 15 km, with a mean normal load range from 3000 to 5000 N, a cutting speed about 1:8 m/ s and a penetration depth close to 2 mm. Analyses are based on models establishing coupled relations between cutting and friction stresses related to the drag bits excavation mechanism. In this work, models are implemented in order to evaluate cutting efficiency and to estimate the life time of the diamond insert. A variety of cutters was characterized by wear rates ranged from 9.4•10^(-15) to 1.1•10^(-13) mm^3/(Nm) (Archard’s model) and cutting efficiencies at 10 km evaluated between 31 and 55%. From here, an original approach is developed to describe the overall cutter quality by defining a ratio between efficiency and wear. The reference samples during preliminary tests clearly revealed various mechanical behaviors due to changes in the material composition and distinct manufacturing production methods. These changes are detected at several levels: coatings, grain sizes, surface roughness, etc.
The current state of PDC bit technology
Part 1 of 3: Development and application of polycrystalline diamond compact bits have overcome complex challenges from the difficulty of reliably mounting PDC cutters in bit bodies to accelerated thermal wear.
Analysis of Temperature Distribution and Performance of Polycrystalline Diamond Compact Bits Under Field Drilling Conditions
Analysis of laboratory tests on full-scale fieldworn polycrystalline diamond compact (PDC) bits showed the frictional heat at the rock/bit interface to be largely generated at the diamond cutting edges of the PDCs. Inspection of the observed wear of the PDCs together with the analysis revealed that the diamond layer attacks the formation at a large negative rake angle and that rock flour accumulates under the cutting edge during drilling, forming a stable buildup edge. The results showed that for effective cooling of the PDCs fluid velocities of at least 50 m/s are required along the diamond surfaces when drilling with oil-based fluids. With water-based drilling fluids, higher velocities should be used to prevent bit balling or boiling of the drilling fluid at the diamond surface of the PDCs.