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.
PDC Bits: All Comes From the Cutter/Rock Interaction
PDC drill bit performances in hard rock has been greatly improved during the last decades by innovations in PDC wear, impact resistance and better vibrations understanding. The bit design is generally done by balancing the bit, distributing uniform wear along the profile and achieving high drillability and steerability. To obtain required drilling performances, drill bit designer adjust features such as profile shape, gage and mainly cutter characteristics (shape, type and orientation). Cutter rock interaction model became a critical feature in the design process. But previously used models considered only three forces on a cutter based on the cutter-rock contact area : drag force, normal force and side force. Such models are no longer valid with the introduction of PDC cutters with chamfer and special shape. This paper presents a new cutter rock interaction model including some several improvements. It is based on the presence of a build-up edge of crushed materials on the cutting face often described in the literature. In addition, the chamfer, which significantly affects bit Rate Of Penetration (ROP), is taken into account (shape and size). Forces applied on the back of the cutter and due to the rock deformation and back flow of crushed materials are considered in the model. Finally, results of numerous single cutter tests (under atmospheric and confining pressure) are presented and compared to the new cutter rock interaction model predictions. An analysis of the influence of the PDC characteristics (shape, size, chamfer, back and side rake angles, ....) is presented. The model has been applied to optimize the cutting efficiency and bit steerability and some design rules are given to minimize the specific energy and maximize the rate of penetration. Finally, full scale laboratory drilling tests and field results indicate that the use of accurate cutter rock interaction model can help the drill bit designer to find the best drill bit for a specific application. Standard laboratory full scale drilling procedures have been developed. The tests have shown that drillability, stability, steerability and wear can be improved and controlled by acting on the cutter characteristics, cutter setup, trimmer characteristics and gage type.
Status of Polycrystalline-Diamond-Compact Bits: Part I Development(includes associated papers 19032 and 19900 )
Polycrystalline-diamond-compact (PDC) bits have become an established new generation of oilfield bits, particularly for drilling soft-to-medium-hard, nonabrasive formations. The development of these bits is still at an exciting stage. The state of the art in PDC cutters and bits is discussed and illustrated by a rich source of fairly recent literature. A look into the future is attempted in light of the bits' potential.