Academic literature on the topic 'Drill-bit breakage'
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Journal articles on the topic "Drill-bit breakage"
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Shi, Hongyan, Xiaoke Lin, and Yun Wang. "Characterization of drill bit breakage in PCB drilling process based on high-speed video analysis." Circuit World 43, no. 3 (2017): 89–96. http://dx.doi.org/10.1108/cw-12-2016-0066.
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Purpose The purposes of this paper are to study the characterization of drill bit breakage in printed circuit board (PCB) drilling process based on high-speed video analysis and to provide an important reference for micro drill bit breakage prediction. Design/methodology/approach Based on PCB drilling experiment, the high-speed camera was used to observe the micro drill breakage process and the chip removal process. The variation of chip in the drilling process was studied and one of the key reasons for the drill bit breakage was analysed. Finally, the swing angles’ feature during the breakage process of the micro drill was analysed and researched with the image processing tools of MATLAB. Findings The micro drill was prone to breakage mainly because of the blocked chips. The breakage process of the micro drill can be divided into the stage of stable chips evacuation, the stage of blocked chips and the stage of drill bit breakage. The radians of swing angles were basically in the range of ±0.01 when the drilling possess is normal. But when the radians of swing angles considerably exceeded the range of ±0.01, the micro drill bit may be fractured. Originality/value This paper presented the method to study the characterization of drill bit breakage in the PCB drilling process by using high-speed video analysis technology. Meanwhile, an effective suggestion about monitoring the radians of swing angles to predict the breakage of micro drill bit was also provided.
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Jeong, Min-Jae, Sang-Woo Lee, Woong-Ki Jang, Hyung-Jin Kim, Young-Ho Seo, and Byeong-Hee Kim. "Prediction of Drill Bit Breakage Using an Infrared Sensor." Sensors 21, no. 8 (2021): 2808. http://dx.doi.org/10.3390/s21082808.
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In this paper, a novel drill bit breakage prediction method featuring a low-cost commercial infrared sensor to monitor drill bit corner wear is proposed. In the proposed method, the drill bit outer corner wear state can be monitored by measuring reflected infrared light because the reflection phenomenon is influenced by wear, edge shape, and surface roughness of the drill bit. In the experiments, a titanium workpiece was drilled without using cutting fluid to accelerate drill bit fracture. After drilling a hole in the workpiece, reflected infrared light was measured for the drill bit rotating at 100 rpm. Collected data on intensity of infrared light reflected from the circumferential surface of the drill bit versus the rotation angle of the drill bit were considered to predict tool breakage; two significant positions to predict tool breakage were found from the reflected infrared light graphs. By defining gradient vectors from the slopes of the reflected infrared light curves, a reliable criterion for determining drill bit breakage could be established. The proposed method offers possibilities for new measurement and analysis methods that have not been used in conventional tool wear and damage studies. The advantage of the proposed method is that the measurement device is easy to install and the measured signal is resistant to electromagnetic noise and ambient temperature because optical fiber is used as the signal transmission medium. It also eliminates the need for complex analysis of the measured signal, eliminating the need for a high-performance analyzer and reducing analysis time.
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Zheng, Hui Meng, Jian Qing Chen, and Shou Xin Zhu. "On-Line Fuzzy Monitoring of Micro-Hole Drilling Based on Genetic Algorithm." Applied Mechanics and Materials 184-185 (June 2012): 1588–91. http://dx.doi.org/10.4028/www.scientific.net/amm.184-185.1588.
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In automated micro-hole drilling system, in order to improve the drilling performance and reduce of production costs by maximizing the use of drill life and preventing drill failures, the drill bit wear state monitoring is more important. However, drill bit wear is difficult to measure in drilling process. By observation, wear failure of the drill bit could cause related changes of the spindle current signal, so construct fuzzy control mathematical models with the relationship between drill bit wear and spindle current, genetic algorithm and fuzzy control theory are applied to micro-drilling system in this paper .The membership functions of fuzzy control model are optimized by genetic algorithms. Through calculation, we can get drill bit wear value which used as monitoring threshold value in micro-hole drilling on-line monitoring system to avoid the drill breakage and improve the monitoring reliability.
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MYRZAKHMETOV, B. A., B. К. MAULETBEKOVA, A. A. MYRZABEKOVA, and Zh K. TATAEVA. "THE FEATURES OF WORK OF CARBIDE-TIPPED DRILL IN CRUMBLING ROCKS." Neft i Gaz 139, no. 1 (2024): 52–60. http://dx.doi.org/10.37878/2708-0080/2024-1.04.
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The drill bit in the oil and gas industry plays a key role in the drilling process, but its operation in the field, filled with difficulties and dangers, emphasizes the need for careful study of its behavior. This equipment, which is the head of the well, is forced to face various challenges during drilling, where danger can await at every step. However, special attention should be paid to those cases when the drill bit collides with crumbling rocks. In conditions of high pressure and friction associated with drilling, the drill bit is subjected to significant loads. These conditions can lead to damage and breakage of equipment, which in turn creates additional risks for workers on site. Understanding the behavior of a drill bit in crumbling rock is becoming an extremely important aspect to ensure the efficiency and safety of field work. The analysis of the technical characteristics and mechanisms of the impact of the drill bit on crumbling rocks makes it possible to develop more reliable and durable tools capable of withstanding extreme conditions. This, in turn, increases drilling efficiency, reduces the risk of industrial accidents and ensures safer working conditions in the oil and gas industry.
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Fu, J. C., C. A. Troy, and P. J. Phillips. "A matching pursuit approach to small drill bit breakage prediction." International Journal of Production Research 37, no. 14 (1999): 3247–61. http://dx.doi.org/10.1080/002075499190266.
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Wang, Jin Song, Pin Lu Cao, and Kun Yin. "Structure Design of and Numerical Simulation on an Annular Reverse Circulation Drill Bit." Applied Mechanics and Materials 733 (February 2015): 558–61. http://dx.doi.org/10.4028/www.scientific.net/amm.733.558.
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The reverse circulation drilling technology of hollow through DTH air hammer is a set of efficient coring with DTH air hammer, full-hole reverse circulation with drilling fluids, and continuous coring without power lack. It been successfully applied in mineral resources exploration, water well drilling, infrastructure construction and other fields. We designed a new type of annular reverse circulation drilling bit in order to prevent drilling accident when drilling in complex strata, such as breakage and leakage. In this paper, the computational fluid dynamics (CFD) code, FLUENT, is employed to simulate the flow phenomena of reverse circulation drill bit. Numerical simulation results show that the values of negative pressure of new type annular reverse circulation drill bit which formed in the center channel and the bottom of hole were larger than those of the normal bit. Under the same conditions, the suction quantity from annulus of annular drilling bit is 1.4 times to the normal one.
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Szwajka, Krzysztof, Joanna Zielińska-Szwajka, Krzysztof Żaba, and Tomasz Trzepieciński. "An Investigation of the Sequential Micro-Laser Drilling and Conventional Re-Drilling of Angled Holes in an Inconel 625 Ni-Based Alloy." Lubricants 11, no. 9 (2023): 384. http://dx.doi.org/10.3390/lubricants11090384.
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The conventional (mechanical) micro-drilling of Inconel 625 alloys suffers from premature breakage of the drill bit due to its brittle nature and limited cutting tool life. Even greater problems are encountered when micro-drilling holes at an acute angle to the machining plane. In such a process, there are great difficulties associated with the low stiffness of the tool, which leads to the frequent breakage of the drill during machining. Therefore, in this type of mechanical drilling operation, the hole surface is usually milled with an end mill to provide a flat surface on the entry side of the drill bit. The aim of this article is to recognise the process of sequential micro-drilling and to assess the possibility of its use as an effective and efficient method of micro-drilling in hard-to-cut metals. The paper describes the process of initial laser drilling followed by final mechanical micro-drilling. Inconel 625 Ni-based alloy sheets were used as the test material. The shape and microstructure of pre-holes made with a laser, the volumetric efficiency of laser processing, the energy in the mechanical drilling process, and tool wear were analysed. The research results show that in the sequential drilling process, mechanical re-drilling eliminates the geometrical discrepancies resulting from the laser pre-drilling. In addition, it was found that, compared to mechanical micro-drilling, the use of sequential micro-drilling resulted in a two-fold increase in drill life. It has been also observed that sequential machining reduces the energy demand by 60% compared to mechanical micro-drilling. In addition, it was found that the edge of the drill bit is a key factor in deciding the target diameter of the laser-drilled pilot hole, and thus in selecting the micro-drilling parameters.
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Ayop, Ahmad Zhafran, Ahmad Zafri Bahruddin, Belladonna Maulianda, et al. "Numerical modeling on drilling fluid and cutter design effect on drilling bit cutter thermal wear and breakdown." Journal of Petroleum Exploration and Production Technology 10, no. 3 (2019): 959–68. http://dx.doi.org/10.1007/s13202-019-00790-7.
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Abstract The unconventional reservoir geological complexity will reduce the drilling bit performance. The drill bit poor performance was the reduction in rate of penetration (ROP) due to bit balling and worn cutter and downhole vibrations that led to polycrystalline diamond compact (PDC) cutter to break prematurely. These poor performances were caused by drilling the transitional formations (interbedded formations) that could create huge imbalance of forces, causing downhole vibration which led to PDC cutter breakage and thermal wear. These consequently caused worn cutter which lowered the ROP. This low performance required necessary improvements in drill bit cutter design. This research investigates thermal–mechanical wear of three specific PDC cutters: standard chamfered, ax, and stinger on the application of heat flux and cooling effect by different drilling fluids by using FEM. Based on simulation results, the best combination to be used was chamfered cutter geometry with OBM or stinger cutter geometry with SBM. Modeling studies require experimental validation of the results.
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Zhou, Hu, Bin Yu, Ning Li, et al. "Preparation and performances of coated and aluminous entry boards with water-soluble resins for PCB drilling." Circuit World 42, no. 4 (2016): 153–61. http://dx.doi.org/10.1108/cw-05-2016-0018.
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Purpose This paper aims to provide a new drilling entry board for printed circuit board (PCB) process, superior in heat dissipation, lubrication, water solubility and hole location accuracy, achieving an excellent drilling process. Design/methodology/approach Using a mixture of polyethylene glycol (PEG) and water-soluble adhesives as hydrosoluble, endothermic and lubricant resins and aluminum foils as baseplates, a series of coated and aluminous entry boards (CABs) for PCB drilling was successfully prepared. The surface appearance of the entry boards was observed clearly by scanning electron microscopy (SEM). The endothermic and lubricant effects of the resins applied on the CABs was characterized by differential scanning calorimetry (DSC) and their water solubility was tested in the normal-temperature water (25°C). Moreover, the CABs’ good drilling properties were tested when they were used for PCB drilling. Findings The SEM analysis showed that the surfaces of the resin layers coated on the CABs whose coating thicknesses were less than 80 μm were smoother and flatter, which could improve hole location accuracy and reduce drill breakage ratio. By virtue of DSC, the endothermic and lubricant effects of the CABs were proven. The fusion of PEG in the resin layers could absorb the heat produced by drilling, restrain the temperature of the drill bit and hole rising and lubricate the drill bit efficiently when a hole was being drilled, which could achieve high-quality holes with good production efficiency. The water-soluble test showed that the prepared CABs had excellent water solubility at normal temperature, enabling the resin left on the hole walls and in the flute of the drill bit to be washed away easily and thereby improving the drilling efficiency and quality. The drilling tests showed that the increase in the thickness of the CABs’ coating could improve the hole location accuracy and alleviate the bit wear. In addition, the suitable coating thickness could ensure the firm adhering of the resin coating the aluminum foil, effectively avoid drill intertwist and prevent the resin debris from blocking the drilled holes on the surface of the entry board, which could hinder chip removal, resulting in poor hole wall quality and drill breakage. Originality/value This paper has a remarkably high industrial practicality in the PCB manufacture process.
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Hase, Alan. "In Situ Measurement of the Machining State in Small-Diameter Drilling by Acoustic Emission Sensing." Coatings 14, no. 2 (2024): 193. http://dx.doi.org/10.3390/coatings14020193.
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In drilling small holes with diameters of 1 mm or less, minute clogging and twining of chips or the adhesion of the workpiece material can become factors in causing breakages of the drill bit; moreover, it can be difficult to identify the machining state. Acoustic emission (AE) sensing is a nondestructive inspection technique that measures the elastic-stress waves that are generated when a material is deformed and fractured. AE sensing permits highly sensitive measurements to be made without changing the rigidity of the experimental system, unlike force sensing of cutting resistance, etc. In the present study, attempts were made to identify the machining state and tool wear, and to predict abnormalities in small-diameter drilling by using the change in the frequency of AE signal waveforms arising from deformation and fracture. It was shown that it is possible to predict the breakage of the drill bit by detecting high-frequency AE signals at about 1 MHz, caused by the adhesion of the workpiece material. In addition, a correlation map of the AE frequency spectrum for identifying the machining state in a drilling operation is suggested.
Dissertations / Theses on the topic "Drill-bit breakage"
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Ho, Tsai Ching, and 蔡青和. "The Non-Stationary Signal Processing of Small Drill Bit Breakage and Electrogastrogram." Thesis, 1998. http://ndltd.ncl.edu.tw/handle/68312189369297039867.
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碩士<br>大葉大學<br>工業工程研究所<br>86<br>In this research, the Wavelet Transform (WT) is used to extract three indices from the thrust cutting force insmall drill bit to predict drill bit breakage. After the machining feature extracted by the WT, a discriminant function is used to classify the drilling status (normal, prefailure). Experimental results showed that the WT does not provide satisfactory classification performances. To improve the classification performances, the Matching Pursuit (MP) is used to search the best basis for the prediction of small drill bit breakage. Experimental results showed that the MP can 100% classify the prefailure signals from the normal signals. ElectroGastroGrams (EGG) is a potential tool for medical diagnosis. In this research, Neural Networks (NN) are used to eliminate the EGG signals caused by motion artifacts. After the EGG signals processed by the NN, the Fast Fourier Transform (FFT) is used to extract three major measurements: Dominant Amplitude (DA), Dominant Frequency (DA) and Area Under Curve (AUC). Experimental results showed that DA and AUC significantly reduced in postprandial period when the period of motion artifacts is more than 80%. To improve the drawbacks of the NN method, the MP is applied to the raw EGG signals to eliminate the signals caused by motion artifacts. In this paper, the MP can effectively point out the beginning of the motion artifacts. Since the MP approach to the EGG signal is still in the early stage, no definite conclusions are made yet.
Conference papers on the topic "Drill-bit breakage"
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Galarraga, Carlos, Gabe Gusey, Derek Wade, and Andrew Allen. "Utilizing Electronic Data Captured, at the Bit, in Combination with Automated Bit Dull Grading, to Improve Bit Design Features, Dull Condition, and Ultimately, Drilling Performance." In SPE/IADC International Drilling Conference and Exhibition. SPE, 2023. http://dx.doi.org/10.2118/212475-ms.
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Abstract Historically, downhole vibrations at the drill bit have been difficult to determine and measure. In addition, oilfield personnel has dull graded bits through visual inspection, which introduces subjectivity into the assessment of the dull condition. Tools to measure dysfunctions at the bit to help understand the root cause of bit failure, and a digital bit imaging system for reliable dull grading, have been a gap in understanding drill bit performance. This paper presents a field study where downhole measurements and automated dull grading were utilized in tandem to improve performance. In the Permian Basin, one of the most challenging applications is the production Vertical+Curve+Lateral section, due to interbedded transitions while drilling, the inability to track tangents, and building curves. The type of vibrations at the bit and their sources were unknown, and determining bit wear location and the type of cutter damage was also a challenge in this case. A sensor at bit to measure downhole dysfunctions, in combination with a digital imaging system that calculates the bit damage, was used to carry out a comprehensive engineering analysis to determine the bit design changes needed for enhanced drilling efficiency. The high-frequency data recorded at the bit showed lateral events of high magnitude that indicated formation-related issues. The automated dull grading system showed catastrophic damage in the cone, along with breakage and delamination of the cutters in the lower shoulder and gauge areas, due to cutter overloading during the lateral vibration events while drilling through hard stringers. The vibrations at the bit were studied to understand how they were generated and how we can mitigate them. The recorded electronic bit data and the outputs of the digital bit dull grading system were analyzed together to determine drill bit features that need to be improved. Based on the bit data recorded and digital dull bit analyses, an advanced bit profile and cutting structure layout with a more impactful placement of depth-of-cut (DOC) control elements were used to develop a fit-for-purpose drill bit design combined with a new generation of PDC cutters. As a result, a complete drill bit design solution was developed to drill longer runs with better dull condition and very consistent performance across the basin. This paper describes the nature of downhole vibrations at the bit and their consequences of damaging the bit through poor drilling performance. A new digital, automated dull grading system accurately determined the detailed location, on the bit, and type of wear produced by the vibrations, and it offered practical recommendations for improving performance. Detailed field data from different runs, showing where bit design changes reduced the failures and resulted in longer intervals drilled, will be presented.
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Xiong, Chao, Xinlong Li, Zhongwei Huang, Huaizhong Shi, Wenhao He, and Zhenliang Chen. "Experimental and Numerical Investigation on Rock Breakage Mechanisms of a Conical Diamond Element." In 57th U.S. Rock Mechanics/Geomechanics Symposium. ARMA, 2023. http://dx.doi.org/10.56952/arma-2023-0015.
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ABSTRACT The conical diamond element (CDE) is an innovative conical-shaped 3D cutter, which exhibits high rock-breaking efficiency in hard formation. But there are few researches on the rock breakage mechanism of CDE cutters. In this paper, a series of single cutter tests were conducted on granite. The rock breakage process, the initiation and propagation of micro-cracks, the surface topography and fracture morphology of the cutting groove and large-size debris were analyzed. A three-dimensional rock cutting model with a CDE cutter was established using the finite element method to study the stress distribution and rock damage evolution during the cutting process. The results show that the cutting process can be divided into two parts: crushing and chipping. There is a spherical stress concentration area formed at the tip of the CDE cutter. The rock breakage mechanism of the CDE cutter can be summarized as follows: the rock at the CDE cutter tip occurs shear-compression failure; the rock in front of the CDE is broken under the tensile action; tensile micro-cracks propagating to the rock inside can deteriorate rock strength. The key findings of this work will help to reveal the rock breakage mechanisms and provide guidelines for CDE bits design. INTRODUCTION Polycrystalline Diamond Compact (PDC) drill bits have been widely used for drilling wells in the exploitation of hydrocarbon and geothermal resources (Bellin et al. 2010) due to the high rock-breaking efficiency and long duration life. However, for deep and ultra-deep drilling, the conventional PDC cutter is facing the challenges of serious impact and wear damage (Brett et al. 2012). In order to improve the drilling performance of PDC drill bits in hard formation, Durrand et al. (2010) invented Conical Diamond Element (CDE), which has nearly twice as thick as polycrystalline diamond layer than the conventional PDC cutter, so the wear resistance and impact resistance is improved approximately 25% and 100% respectively (Azar et al. 2013). Since CDE was invented, the hybrid PDC drill bit, on which the CDE is strategically positioned at the bit center or behind the primary conventional PDC cutter, has drilled more than 26 million feet in hard and interbed formation. Based on the records, the hybrid PDC bits increased footage up to 77% with corresponding Rate of Penetration (ROP) increases up to 29% in the Permian Basin (Radhakrishnan et al. 2016).
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Lee, JuEun, Serena Chu, and Craig L. Chavez. "Investigation of Forces in Deep Hole Bone Drilling." In ASME 2018 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/imece2018-87064.
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Deep hole drilling is required to install prosthetic devices in surgical implantation. Compared to the common bone drilling processes, deep hole bone drilling is performed with a larger hole depth (i.e., up to a depth of approximately 35 mm in cochlear implantation) using a high ratio of the length to diameter of the drill bit. For successful outcomes from this process, forces must be controlled adequately to avoid other complications such as drill-bit breakage or thermal necrosis. This study investigates the thrust force and torque generated in bone drilling process of up to 36 mm drilling depth. Drilling tests were performed on bovine cortical bone using 2.5 mm diameter twist drill bit with a spindle speed of 3000 rpm, and feed rates of 0.05, 0.075, and 0.1 mm/rev. Two distinct states in both the thrust force and torque data were observed for all conditions, which are called normal and abnormal states in this study. At an early stage of the drilling process, the force signals showed the traditional trend, reaching a constant value once the tip of the drill bit was fully engaged in bone cutting up to a certain depth. After that, both thrust force and torque kept increasing rapidly until the final drilling depth. This study also observed that the chip morphology varies with increasing drilling depth, showing fragmented chips at the normal state and powdery chips at the abnormal state. Chip clogging and increased frictional force between chips, tool, and hole wall with larger drilling depth may cause the abrupt increase in forces and variation in chip morphology.
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Russell, S. Craig, Stephen Duffy, and Oliver Matthews. "Shaped Cutter Performance Optimization Through Advanced Drilling Simulations." In IADC/SPE International Drilling Conference and Exhibition. SPE, 2022. http://dx.doi.org/10.2118/208681-ms.
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Abstract Historically polycrystalline diamond compact cutters have consisted of a planar cutting face on a cylindrical diamond table. For decades industry has been aware of the potential drilling performance gains from forming these cylindrical cutters into other geometrical shapes. These early generation shaped cutters did not gain traction due to limitations in diamond technology, and high manufacturing costs associated with shaping the cutters. Recently PDC drill bits with shaped cutter designs are becoming more prolific in worldwide drilling applications. Often, the novelty in the design of the cutter shapes is enticing enough to merit opportunities for field runs. However, without an informed understanding of shaped cutter behaviors, there is risk of diminished drilling performance if the cutter shapes are not applied properly to the bit and application. The objective of this paper is to develop methods to evaluate two critical behaviors for shaped PDC cutter designs, overload integrity and aggressivity, and apply these methods to a full bit drilling model. The cutter overload integrity characterization methods are developed using finite element analysis and the aggressivity characterization is based on high pressure visual single point cutter laboratory test data. The information is fed into a full bit drilling numerical model to predict bit performance and ability to avoid cutter breakage in a simulated drilling environment, accounting for factors such as lithology, interbedded transitions, bottom hole assembly type, and operating parameters. The models enable optimization of shaped cutter design and fit for purpose cutter selection. The full bit model is tested and validated against field runs. Case studies include interbedded drilling in the Haynesville and Permian Basins. In both applications, bits were run with different shaped cutter designs, using drilling performance and dull photos to compare to the model outputs. ROP gains of 35% were seen in the Haynesville application, while the cutter survival rate more than doubled in the Permian application by using optimally selected shaped cutters. The methods presented in this paper provide new pathways for shaped cutter design and selection. Digital tools are demonstrated to perform the multi-faceted analysis efficiently for pre-well planning and post-run analysis.
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Centala, P. K., and T. S. Roberts. "Shaping the Future with PDC Cutter Technology, Progress, and Next Steps." In SPE/IADC International Drilling Conference and Exhibition. SPE, 2025. https://doi.org/10.2118/223687-ms.
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Abstract Recent improvements in Polycrystalline Diamond Compact (PDC) cutter technology manufacturing capability have led to denser, stronger diamond structures with much greater durability. The step change has made it possible to implement complex geometry PDC cutters on a much wider scale. This paper demonstrates the development of application-specific shape PDC cutters over the past decade, which provide greater drilling efficiency in various rock formations without sacrificing durability, benefiting the drilling industry. Over a 10-year period, a range of new complex geometry cutters that are more efficient and durable were developed and designed for greater drilling performance. Detailed research focused on improved rock failure mechanics. Analytical and experimental methods were used to optimize for greater impact strength to withstand breakage under high loading conditions. Pressurized single-cutter tests simulating downhole conditions were performed, measuring both axial and shearing forces on multiple new geometries with various rock types. Finally, these were complemented with full-scale drill bit tests prior to field testing in challenging applications globally. Single-cutter laboratory test results demonstrated that optimizing the diamond table geometry can improve performance with different rock formations. In many cases, lower forces and torque were measured while drilling, indicating greater drilling efficiency. In other examples, specifically enhanced geometry provided increased robustness. Under high loading conditions, the engineered geometry absorbed higher impacts without loss of structural integrity. The evaluation of five specific cutter geometries based on their drilling efficiency and durability illustrated that each provided individual benefits in certain rock types. Some were better suited for clastic carbonate-type formations, while others provided greater durability in harder interbedded limestones and conglomerates. A review of each of the five geometries will be presented, demonstrating their advantages. Standard round PDC cutters have dominated for almost 50 years, with thousands of bit iterations providing incremental advancements for the drilling industry. This research and development clearly show the benefits of novel PDC geometries and how they provide far greater drilling performance. The intricate process outlined is beneficial to the industry.
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Sun, Yuqi, Li Liu, Haichao Jiang, et al. "Research on the Rock Cutting Mechanism of Non-Planar PDC Cutters Based on the Drucker-Prager Criterion." In 57th U.S. Rock Mechanics/Geomechanics Symposium. ARMA, 2023. http://dx.doi.org/10.56952/arma-2023-0556.
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ABSTRACT Non-planar PDC cutters are widely used to solve these problems of wear and breakage of conventional PDC cutters when drilling hard rock formations. In this paper, the finite element method is adopted to study the rock-breaking characteristics of non-planar PDC cutters. The effects of the cutting parameters on the rock-breaking efficiency of a non-planar PDC cutter are analyzed. The mechanical specific energy (MSE) of non-planar PDC cutters is smaller. The rate of penetration (ROP) is higher, and the aggressiveness is stronger. The influence of different cutting parameters on the rock-breaking efficiency of four types of PDC cutters is analyzed. The results indicate that the optimum cutting depth is in the range of 1.5-2 mm, and the optimum cutting angle is in the range of 15°-20°. Based on the finite element simulation results, a personalized PDC bit is designed and successfully applied to Yang101HXX-3 well. The research results can provide a theoretical basis for the selection, structure optimization, drilling bit design, and application of efficient PDC bits. INTRODUCTION Oil and natural gas resources are the main energy sources in today's society, which have a bearing on people's livelihoods and national defense security. Polycrystalline diamond compact (PDC) fixed-cutting bits (PDC bits) have continued to evolve and advance since they were first introduced in 1973 and entered the field in 1976. With the increasing level of oil and gas exploration and development, the number of deep and ultra-deep wells is gradually increasing. The geological conditions are becoming more complex. In complex and difficult to drill formations such as deep hard formations, abrasive formations, and soft and hard interlocking formations, conventional PDC drill bits have certain limitations. There are problems such as low mechanical drilling speed, difficulty in drilling, low drilling efficiency, and a short working life (Wang et al., 2021). PDC cutters crushing of rock is divided into two processes. First, PDC cutters intrude into the rock. Then, PDC cutters cause the surrounding rock to crumble into large pieces, and the rock undergoes shear damage (Almenara & Detournay, 1992). The durability of conventional PDC cutters depends on the wear resistance of the diamond (Wang et al., 2019). In addition, the flat working surface of conventional PDC cutters obstructs rock debris transport, which tends to cause repeated cutting. The rock-breaking efficiency of PDC bits is not only influenced by drilling parameters, formation lithology, and PDC bit structure, but also related to the shape of PDC cutters. In recent years, various non-planar PDC cutters have been used in the design of PDC bits, such as ridged PDC cutters, triridged PDC cutters, and stinger PDC cutters, as shown in Fig. 1, which have achieved good speed-up results in specific formations. Non-planar PDC cutters can enhance the impact and wear resistance of PDC bits in hard formations, reduce the mechanical specific energy (MSE) of the rock, and improve the rate of penetration (ROP).