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Fixed Cutter Bits: Early Diamond Bit History

This document provides an overview of different types of fixed cutter bits used in drilling operations, including their history, design, and applications. It discusses early use of natural diamonds in bits and key milestones like the development of polycrystalline diamond compact (PDC) cutters. The document also outlines different cutter technologies like natural diamonds, thermally stable polycrystalline cutters, impregnated cutters, and PDC cutters. It describes factors in bit design like cutter layout, blade count, volume of rock removed, and gauge design. Applications of different cutter technologies based on formation hardness are also summarized.

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Tim Clarke
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311 views24 pages

Fixed Cutter Bits: Early Diamond Bit History

This document provides an overview of different types of fixed cutter bits used in drilling operations, including their history, design, and applications. It discusses early use of natural diamonds in bits and key milestones like the development of polycrystalline diamond compact (PDC) cutters. The document also outlines different cutter technologies like natural diamonds, thermally stable polycrystalline cutters, impregnated cutters, and PDC cutters. It describes factors in bit design like cutter layout, blade count, volume of rock removed, and gauge design. Applications of different cutter technologies based on formation hardness are also summarized.

Uploaded by

Tim Clarke
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Fixed Cutter Bits

Early Diamond Bit History

Prior to 1940 natural diamonds were peened

into a steel head to create a diamond bit. Due to the high cost and marginal manufacturing technique, diamond drill bit were rarely used. The primary diamond application was in core bits.

Milestones
1947 - Christensen Develops matrix bit

technology for practical attachment of natural diamonds to a drill or core bit head. 1954 - GE is the first to synthesize diamond. 1975 - First practical application of man-made diamond with introduction of GEs Stratapax polycrystalline diamond compact (PDC) stud cutter. 1981 - Introduction of thermally stable polycrystalline (TSP) cutters.

PDC Design Presentation


Cutter Technology PDC Bit Design Profiles and Blades Cutter Orientations Hydraulics Bit Gauge Bit Mechanics Design Optimization

Natural Diamond Cutters

Original diamond cutting element. Monocrystalline diamond. Different size and quality diamonds for different

applications. Size range expressed as stones per carat (SPC).

Natural Diamond Cutters


Natural diamonds are

furnaced into the bit head. Versatile application range when synthetic diamonds are not applicable. Medium to very hard formations. Fixed TFA.

Ballaset Cutters

Thermally Stable Polycrystalline (TSP)

diamond cutters. Extension of PDC cutter technology. Cutter size expressed as stones per carat (SPC).

Ballaset Cutters
Thermal stability allows

cutters to be directly furnaced into the bit. Developed for medium to hard applications, particularly carbonates. Fixed Total Flow Area (TFA).

Impregnated Cutters
Diamond grit is hot-

pressed into tungsten carbide matrix to form impregnated segments. Diamond grit is synthetic diamond material.

Impregnated Cutters

Pre-formed segments furnaced

directly into bit crown. Grinding tool for very hard and abrasive applications. Especially effective at high rotation speeds.

Polycrystalline Diamond Compact

Diamond Table Tungsten Carbide Substrate

Conventional PDC Cutter

PDC Cutter Sizes


0.750 - 19 mm 0.529 - 13.3 mm 0.323 - 8.2 mm

0.642 - 16 mm 0.315 - 8 mm 0.315 - 8 mm

Sharp vs. Chamfered Cutting Action

Failure Plane

Failure Plane

Polished Cutters

Built-Up Edge

Polished Cutter

Carbide Supported Edge


CSE Cutter
Chamfer Angle Tungsten Carbide Body

Standard Cutter

Cutting Force

CSE Geometry Strengthens The Diamond Edge Against The Cutting Force

Materials & Bit Construction


API Connection Nozzles Junk Slot Area Weld Blank Blank Blade Matrix Body PDC Gauge Cutters PDC Cutters PDC Face Cutters Cone Nose Nozzle Shoulder Crown Chamfer Stamp Area - Serial # - Style - TFA - ND/Ballaset Breaker Slot

Gauge Pad

Bit Profiles
Bit profile and cutter layout are closely related. Layout is a compromise between the following: Maximum number of cutters (longer bit life) Lowest blade count (better hydraulics, penetration rate) Shortest possible profile (better bit stability and cleaning)

Volume of Rock Removed


Volume of rock removed is a

function of Cutter radius Depth of cut Width of cut There is a direct relationship between the volume of rock removed and the work rate of a cutter.

Volume of Rock Removed


The volume of rock
5

Vorr (in3)

4 3 2 1 0 1 2 3 4

Cutter #
60 RPM, 60 ft./hr

removed is calculated for a given penetration rate (depth of cut). We use profile and blade count to manipulate the amount of work done in each area of the bit.

Blade Count & Cutter Density

LIGHT

MEDIUM

HEAVY

Blade Strength
Tapered blades provide optimum
Blade Length Blade Height Blade Width

Root Radius Force

strength and hydraulic efficiency The blade strength is calculated using the blade height, width, length and the leading edge root radius. Blade strength is given as a percentage of the API connection strength. (i.e., 204%)

Conventional Blade Configuration

Backrake & Siderake

Single Cutter Forces

Depth of Cut

F Torque Fwob

Fn Fs

Fwob

Fwob

Fn Fs

A cutter will see a different magnitude & direction of

forces depending on its location on the bit profile.

Resultant Cutter Force Vector


Group #2 Group #2 Group #1 Group #3
Ne

Group #1
rce e Fo lanc a b t Im

Group #4

Group #3 Group #4

Force Vector Groups

Force Vector Summation

Gauge Design
The gauge is considered the

PDC Bit Gauge

stabilizing, full hole section of a bit. Gauge begins at the gauge point and continues up to the crown chamfer. Typical materials include natural diamonds and tungsten carbide segments. For optimum stability a flush set gauge pad is used.

Anti-Whirl Force Balancing


Cutter layout &

orientation are purposely designed to create a net imbalance force, pushing the bit against the hole wall and creating a stable rotating condition.

PDC Applications
100,000 90,000 80,000 70,000 UCS (psi) 60,000 50,000 40,000 30,000 20,000 10,000 Quartzite (metamorphic) Granite Marble Sandstone Limestone (Igneous) (metamorphic) Marlstone SEC PDC Application Limit Standard PDC Limit

IADC Dull Grading System


Cutting Structure Inner Rows Bearing Gauge Gauge Comments Other Characteristic Reason Pulled

Outer Dull Location Bearing Rows Characteristic & Seal X

Cutter Wear

Bit Dull / Other Characteristics


BC - Broken Cone BF - Bond Failure BT - Broken Teeth/Cutters BU - Balled Up CC - Cracked Cone CD - Cone Dragged CI - Cone Interference CR - Cored CT - Chipped Teeth/Cutters ER - Erosion FC - Flat Crested Wear HC - Heat Checking JD - Junk Damage LC - Lost Cone LN - Lost Nozzle LT - Lost Teeth/Cutters NR - Not Rerunnable OC - Off-Center Wear PB - Pinched Bit PN - Plugged Nozzle/Flow Area RG - Rounded Gauge RO - Ring Out RR - Rerunnable SD - Shirttail Damage SS - Self-Sharpening Wear TR - Tracking WO - Wash Out on Bit WT - Worn teeth/Cutters NO - No Other Major Dull Characteristics

Fixed Cutter Bit Profiles

A - All over C - Cone - shown on all profiles N - Nose - Part of profile that would rest on the table if bit set upside down T Taper Straight portion tangent to nose and shoulder S - Shoulder - Outer area adjacent to the nose and gauge areas G - Gauge - Area ground to API specifications and cuts a gauge hole

Worn Cutter

Diamond Lip

Worn Cutter

Chipped Cutter

Broken Cutters

Lost Cutters

Heat Checking

Erosion

Ring Out

Junk Damage

Cored

Broken Blade

Balled

Plugged Nozzle

Acknowledgement
We wish to thank the Hughes Christensen division of Baker Hughes for their valuable assistance in the preparation of this material.

Notes: __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________

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