University Of Tripoli

Faculty Of Engineering
Petroleum Engineering Department

Bit Design

Prepared By: Reem Khaled aldaghari.

Student No. 022130898.

Spring 2017
 Abstract

Bit design is an important process in drilling operation that makes the

drilling operation more efficient and sometimes to achieve the drilling
operation with low cost.

Selection of bit type is the first step of bit design, this selection most be
cover the technical an economical sides, after that bit design will be done,
each type have a different way to made its design.
 Dedication

I dedicate this to my wonderful Mom and Dad, it's impossible to thank you
adequately for everything you've done for me, from loving me
unconditionally to raising me in a stable household. For all of my loved ones
who've gone on to a better life, especially my grandfathers you are always
close in heart. For all of my friends old and new thanks for always being
there for me! For the special person who made my life so beautiful and
who's always there by my side supporting me May Allah bless you!
 Acknowledgement

My deepest gratitude goes to Allah who has provided all that was needed to
complete this report, Then my University where I have been trained to take
up my destiny of royalty and dominion.
I am and will forever be grateful to my loving parents who have given
everything possible and even given up important things to make sure I
achieve this feat. I cant find the words that express my gratitude. I also from
the depth of my heart appreciate the help and guidance that I've got from
Eng.Ali Abukhzam to achieve all this.

Table of content
1. Introduction..................................................................... 1

2. Literature reviews............................................................8

3. Roller cone bit design.....................................................12

3.1. Goals of roller cone bit design............................................12
3.2. Roller cone bit design method............................................13
3.2.1. Bit diameter/available space.......................................................13
3.2.2. Journal angle................................................................................14
3.2.3. Cone offset..................................................................................14
3.2.4. Teeth and inserts.........................................................................15
3.3. Materials design................................................................18

4. Polycrystalline Diamond Compact (PDC) bit design...........22

4.1. Factors affecting bit design and performance.....................22
4.2. Geometric parameters of PDC bit design............................22
4.3. Cutting structure characteristics........................................23
4.3.1. Cutting mechanics.......................................................................23
4.4. Cutters.............................................................................26
4.4.1. Components of PDC cutter..........................................................27
4.4.2. Cutter optimization......................................................................29

5. Selecting a drill bit.........................................................31

5.1. Rules of thumb for bit selection.........................................31
5.2. Tripping can ruin a new bit................................................32
5.3. Establish a bottom hole pattern.........................................32
5.4. Use a drill-off test to select best weight on bit (WOB) and
speed......................................................................................32
5.5. The bit is not always to blame for low ROP.........................33
5.6. Drill bit economics.............................................................33

6. Conclusions...................................................................35

7. References....................................................................38
Table of figures
FIGURE 1-1:DIFFERENT BIT TYPES (FROM LEFT TO RIGHT: PDC, TCI, AND MILLED-
TOOTH BITS)....................................................................................................... 1
FIGURE 1-2: MILLED TOOTH BIT....................................................................................3
FIGURE 1-3 : INSERT BITS............................................................................................. 3
FIGURE 1-4 : ELEMENTS OF ROLLER CONE BIT.............................................................5
FIGURE 1-5 : PDC BITS................................................................................................. 7
FIGURE 3-1 :COMPARISON OF SOFTER (LEFT) AND HARDER (RIGHT) CUTTING
STRUCTURES..................................................................................................... 18
FIGURE 4-1: FORMATION FAILURE FROM STRESS AND STRAIN...................................24
FIGURE 4-2:SHEAR AND THRUST ON A CUTTER.........................................................25
FIGURE 4-3:TYPICAL GEOMETRIES BETWEEN DIAMOND TABLES AND SUBSTRATES.. .28
FIGURE 4-4:CUTTER SECTION SHOWING DIAMOND TABLE AND INTERFACE STYLE.....29
FIGURE 4-5:EXAMPLES OF SPECIAL-PURPOSE AND EXTREME SERVICE CUTTERS.......30
Table of tables
TABLE 3-1 :INTERRELATIONSHIP BETWEEN INSERTS, TEETH, AND THE FORMATION.. 16
TABLE 3-2 : COMPARISON OF DIAMOND, PDC, AND TUNGSTEN CARBIDE MATERIALS.
.......................................................................................................................... 21
1.

2. Introduction
Rotary drilling uses two types of drill bits, roller cone bits and fixed cutter
bits. Roller cone bits are generally used to drill a wide variety of formations,
from very soft to very hard. Milled tooth (or steel-tooth) bits are typically
used for drilling relatively soft formations. Tungsten carbide inserts bits
(TCI) or button bits are used in a wider range of formations, including the
hardest and most abrasive drilling applications see Figure 1-1. Fixed-cutter
bits, including polycrystalline diamond compact (PDC), impregnated, and
diamond bits, can drill an extensive array of formations at various depths.
The following material outlines design considerations and general product
characteristics for the two types.

Figure 1-1:Different bit types (from left to right: PDC, TCI, and milled-tooth bits).
There are basically three types of drilling bit:

Drag Bits
Roller Cone Bits
Diamond Bits

Drag bits were the first bits used in rotary drilling but are no longer in
common use. A drag bit consists of rigid steel blades shaped like a fish tail
which rotate as a single unit. These simple designs were used up to 1900 to
successfully drill through soft formations. The introduction of hard facing to
the surface of the blades and the design of fluid passageways greatly
improved its performance. Due to the dragging/scraping action of this type
of bit, high RPM and low WOB are applied. The decline in the use of drag
bits was due to:

The introduction of roller cone bits, which could drill soft formations
more efficiently
If too much WOB was applied, excessive torque led to bit failure or
drill pipe failure
Drag bits tend to drill crooked hole, therefore some means of
controlling deviation was required
Drag bits were limited to drilling through uniformly, soft,
unconsolidated formations where there were no hard abrasive layers.

Roller cone bits (or rock bits) are still the most common type of bit used
worldwide. The cutting action is provided by cones, which have either steel
teeth or tungsten carbide inserts. These cones rotate on the bottom of the
hole and drill hole predominantly with a grinding and chipping action. Rock
bits are classified as milled tooth bits or insert bits depending on the cutting
surface on the cones Figure 1-2 and 1-3.

Figure 1-2: Milled tooth bit.

Figure 1-3 : insert bits.

Hughes designed the first successful roller cone bit in 1909. This was a
major innovation since it allowed rotary drilling to be extended to hard
formations. The first design was a 2-cone bit, which frequently balled up
since the teeth on the cones did not mesh. This led to the introduction of a
superior design in the 1930s, which had 3-cones with meshing teeth. The
same basic design is still in use today although there have been many
improvements over the years.

The cones of the 3-cone bit are mounted on bearing pins, or arm journals,
which extend from the bit body. The bearings allow each cone to turn about
its own axis as the bit is rotated. The use of 3-cones allows an even
distribution of weight, a balanced cutting structure and drills a better gauge
hole than the 2-cone design. The major advances in rock bit design since the
introduction of the Hughes rock bit include:

Improved cleaning action by using jet nozzles.

Using tungsten carbide for hard facing and gauge protection.

The introduction of sealed bearings to prevent the mud causing

premature failure due to abrasion and corrosion of the bearings. The
elements of a roller cone bit are shown in detail in Figure 1-4.
 Figure 1-4 : Elements of roller cone bit.

Diamond has been used as a material for cutting rock for many years. Since
it was first used, however, the type of diamond and the way in which it is set
in the drilling bit have changed.

The hardness and wear resistance of diamond made it an obvious material to

be used for a drilling bit. The diamond bit is really a type of drag bit since it
has no moving cones and operates as a single unit. Industrial diamonds have
been used for many years in drill bits and in core heads Figure 1-1.
The cutting action of a diamond bit is achieved by scraping away the rock.
The diamonds are set in a specially designed pattern and bonded into a
matrix material set on a steel body. Despite its high wear resistance diamond
is sensitive to shock and vibration and, therefore, great care must be taken
when running a diamond bit.

Effective fluid circulation across the face of the bit is also very important to
prevent overheating of the diamonds and matrix material and to prevent the
face of the bit becoming smeared with the rock cuttings (bit balling).
The major disadvantage of diamond bits is their cost (sometimes 10 times
more expensive than a similar sized rock bit). There is also no guarantee that
these bits will achieve a higher ROP than a correctly selected roller cone bit
in the same formation.

They are however cost effective when drilling formations where long
rotating hours (200-300 hours per bit) are required. Since diamond bits have
no moving parts they tend to last longer than roller cone bits and can be used
for extremely long bit runs.
This results in a reduction in the number of round trips and offsets the
capital cost of the bit. This is especially important in areas where operating
costs are high (e.g. offshore drilling). In addition, the diamonds of a
diamond bit can be extracted, so that a used bit does have some salvage
value.

A new generation of diamond bits known as polycrystalline diamond

compact (PDC) bits was introduced in the 1980s Figure 1-5. These bits have
the same advantages and disadvantages as natural diamond bits but use
small discs of synthetic diamond to provide the scraping cutting surface.

Figure 1-5 : PDC bits.

The small discs may be manufactured in any size and shape and are not
sensitive to failure along cleavage planes as with natural diamond. PDC bits
have been run very successfully in many areas around the world. They have
been particularly successful (long bit runs and high ROP) when run in
combination with turbo drills and oil based mud.
3. Literature reviews
Drill bits vary in their design and construction so that different materials can
be drilled efficiently. Most general purpose twist drills are designed to bore a
variety of materials well, but no single material most efficiently. The
differences most effecting performance is the design of the cutting tip, flute
shape and material they are made from.

The biggest single factor effecting longevity of a drill bit is heat. When
sufficient heat is generated at the cutting edges of a drill bit, the edges
deform and the bit becomes dull or "burned". A burned drill bit has had the
temper of the material negatively affected and renders the bit nearly useless
without extensive re-grinding. If enough heat is generated to melt the
material being drilled, a build up can occur on the tip and prevent efficient
drilling as well. The amount of heat generated at the tip while drilling is
effected by the material being drilled (hardness and melting point), the speed
of the drill (RPM) and the rate at which the drill bit is being fed into the
material (feed rate). The use of cutting fluids dissipates heat away from the
cutting edges and is recommended on hard drilling operations and some
materials with low melting points.

Typical twist drill bits have either a 118 or 135 angle ground at the tip. The
118 tip provides for more cutting surface and is best suited for softer
materials (wood, plastic, aluminum). This greater cutting surface allows for
more material to be cut with each revolution providing faster drilling. The
135 tip allows less cutting edge surface, but permits more efficient drilling
of harder materials (steel, stainless steel). Given the same conditions
(material, RPM and feed rate) the 118 point will produce more heat than the
135.
4. Roller cone bit design
Wide varieties of roller cone bits are available. They provide optimum
performance in specific formations and/or particular drilling environments,
Modern drill bits incorporate significantly different cutting structures and
use widely improved materials, resulting in improved bit efficiency.
Manufacturers work closely with drilling companies to collect information
about their bits to identify opportunities for design improvements.

4.1. Goals of roller cone bit design

The goals of roller cone bit design is expect the bit to do its functions at a
low cost per foot drilled with a long down hole life that minimizes
requirements for tripping and provide stable and vibration free operation at
the intended rotational speed and weight on bit (WOB) and give a cut gauge
accurately throughout the life of the bit, at seem time.

To achieve these goals, bit designers consider several factors, the most
important factors are, the formation and drilling environment, expected
rotary speed, expected weight on bit (WOB), hydraulic arrangements, and
Anticipated wear rates from abrasion and impact.

Roller cone bit design is essentially focus on the bit body, cone
configurations, cutting structures, metallurgical, tribological, and hydraulic
considerations in engineering bit design solutions.
 4.2. Roller cone bit design method
The bit geometry and cutting structure engineering method of Bentson have
since 1956 been the root from which most roller cone bit design methods
have been designed. Although modern engineering techniques and tools
have advanced dramatically from those used in 1956, Bentsons method is
the heritage of modern design and continues to be useful for background
explanation.

4.2.1. Bit diameter/available space

Well diameter and the bit diameter required to achieve it influence every
design feature incorporated into every efficient bit. The first consideration in
the physical design of a roller cone bit is the permissible bit diameter or, in
the words of the designer, available space. Every element of a roller cone bit
must fit within a circle representative of the required well diameter. The API
has issued specifications establishing permissible tolerances for standard bit
diameters. The sizes of journals, bearings, cones, and hydraulic and
lubrication features are collectively governed by the circular cross section of
the well. Individually, the sizing of the various elements can, to an extent, be
varied. Repositioning or altering the size or shape of a single component
nearly always requires subsequent additional changes in one or more of the
other components. In smaller bits, finding good compromises can be
difficult because of a shortage of space.
 4.2.2. Journal angle
Journal angle describes an angle formed by a line perpendicular to the axis
of a bit and the axis of the bits leg journal. Journal angle is usually the first
element in a roller-cone bit design. It optimizes bit insert (or tooth)
penetration into the formation being drilled; generally, bits with relatively
small journal angles are best suited for drilling in softer formations, and
those with larger angles perform best in harder formations.

4.2.3. Cone offset

To increase the skidding-gouging action, bit designers generate additional
working force by offsetting the centerlines of the cones so that they do not
intersect at a common point on the bit. This cone offset is defined as the
horizontal distance between the axis of a bit and the vertical plane through
the axis of its journal. Offset forces a cone to turn within the limits of the
hole rather than on its own axis. Offset is established by moving the
centerline of a cone away from the centerline of the bit in such a way that a
vertical plane through the cone centerline is parallel to the vertical centerline
of the bit. Basic cone geometry is directly affected by increases or decreases
in either journal or offset angles, and a change in one of the two requires a
compensating change in the other. Skidding-gouging improves penetration
in soft and medium formations at the expense of increased insert or tooth
wear. In abrasive formations, offset can reduce cutting structure service life
to an impractical level. Bit designers thus limit the use of offset so that
results just meet requirements for formation penetration.
 4.2.4. Teeth and inserts

Tooth and insert design is governed primarily by structural requirements for

the insert or tooth and formation requirements, such as:

Penetration.
Impact.
Abrasion.
With borehole diameter and knowledge of formation requirements, the
designer selects structurally satisfactory cutting elements (steel teeth or
Tungsten Carbide Inserts (TCIs) that provide an optimum insert/tooth
pattern for efficient drilling of the formation.

Factors that must be considered to design an efficient insert/tooth and

establish an advantageous bottom hole pattern include:

Bearing assembly arrangement.

Cone offset angle.
Journal angle.
Cone profile angles.
Insert/tooth material.
Insert/tooth count.
Insert/tooth spacing.
When these requirements have been satisfied, remaining space is allocated
between insert/tooth contour and cutting structure geometry to best suit the
formation.
In general, the physical appearance of cutting structures designed for soft,
medium, and hard formations can readily be recognized by the length and
geometric arrangement of their cutting elements.

Because formations are not homogeneous, sizable variations exist in their

drill ability and have a large impact on cutting structure geometry. For a
given WOB, wide spacing between inserts or teeth results in improved
penetration and relatively higher lateral loading on the inserts or teeth.
Closely spacing inserts or teeth reduces loading at the expense of reduced
penetration. The design of inserts and teeth themselves depends largely on
the hardness and drill ability of the formation. Penetration of inserts and
teeth, cuttings production rate, and hydraulic requirements are interrelated,
as shown in table 3-1.

Table 3-1 :Interrelationship Between Inserts, Teeth, Hydraulic Requirements, And The Formation.

Formation and cuttings removal influence cutting structure design. Soft,

low-compressive-strength formations require long, sharp, and widely spaced
inserts/teeth. The penetration rate in this type of formation is partially a
function of insert/tooth length, and maximum insert/tooth depth must be
used.
Limits for maximum insert/tooth length are dictated by minimum
requirements for cone-shell thickness and bearing structure size. Insert/tooth
spacing must be sufficiently large to ensure efficient fluid flows for cleaning
and cuttings evacuation.

Requirements for hard, high-compressive-strength formation bits are usually

the direct opposite of those for soft formation types. Inserts are shallow,
heavy, and closely spaced.

Because of the abrasiveness of most hard formations and the chipping action
associated with the drilling of hard formations, the teeth must be closely
spaced as shown in figure 3-1.

This close spacing distributes loading widely to minimize insert/tooth wear

rates and to limit lateral loading on individual teeth. At the same time,
inserts are stubby and milled tooth angles are large to withstand the heavy
WOB loadings required to overcome the formations compressive strength.
Close spacing often limits the size of inserts/teeth.

In softer and, to some extent, medium-hardness formations, formation

characteristics are such that provisions for efficient cleaning require careful
attention from designers. If cutting structure geometry does not promote
cuttings removal, bit penetration will be impeded and force the rate of
penetration (ROP) to decrease. Conversely, successful cutting structure
engineering encourages both cone shell cleaning and cuttings removal.
 Figure 3-6 :Comparison of softer (left) and harder (right) cutting structures.

4.3. Materials design

Materials properties are a crucial aspect of roller-cone bit performance.
Components must be resistant to abrasive wear, erosion, and impact loading.
The eventual performance and longevity results for a bit take into account
several metallurgical characteristics, such as:

Heat treatment properties.

Weld ability.
 The capacity to accept hard facing without damage.
Machinability.
Physical properties for bit components are contingent on the raw material
from which a component is constructed, the way the material has been
processed, and the type of heat treatment that has been applied. Steels used
in roller-cone bit components are all melted to exacting chemistries,
cleanliness, and interior properties. All are wrought because of grain
structure refinements obtained by the rolling process. Most manufacturers
begin with forged blanks for both cones and legs, because of further
refinement and orientation of microstructure that results from the forging
process.

Structural requirements and the need for abrasion and erosion resistance are
different for roller-cone bit legs and cones. Predictably, the materials from
which these components are constructed are normally matched to the special
needs of the component. Furthermore, different sections of a component
often require different physical properties. Leg journal sections, for example,
require high hard inabilities that resist wearing from bearing loads, whereas
the upper portion of legs is configured to provide high tensile strengths that
can support large structural loads.

Roller cone bit legs and cones are manufactured from low alloy steels. Legs
are made of a material that is easily machinable before heat treatment, is
weldable, has high tensile strength, and can be hardened to a relatively high
degree. Cones are made from materials that can be easily machined when
soft, are weldable when soft, and can be case hardened to provide higher
resistance to abrasion and erosion.
Tungsten carbide is one of the hardest materials known. Its hardness makes
it extremely useful as a cutting and abrasion resisting material for roller cone
bits. The compressive strength of tungsten carbide is much greater than its
tensile strength. It is thus a material whose usefulness is fully gained only
when a design maximizes compressive loading while minimizing shear and
tension. Tungsten carbide is the most popular material for drill bit cutting
elements. Hard facing materials containing tungsten carbide grains are the
standard for protection against abrasive wear on bit surfaces.

When most people say tungsten carbide, they do not refer to the chemical
compound (WC) but rather to a sintered composite of tungsten carbide
grains embedded in, and metallurgic ally bonded to, a ductile matrix or
binder phase. Such materials are included in a family of materials called
ceramic metal, or cermet. Binders support tungsten carbide grains and
provide tensile strength. Because of binders, cutters can be formed into
useful shapes that orient tungsten carbide grains so they will be loaded under
compression. Tungsten carbide cermet can also be polished to very smooth
finishes that reduce sliding friction. Through the controlled grain size and
binder content, hardness and strength properties of tungsten carbide cermet
are tailored for specific cutting or abrasion resistances.

The most common binder metals used with tungsten carbide are iron, nickel,
and cobalt. These materials are related to the periodic table of elements and
have an affinity for tungsten carbide (cobalt has the greatest affinity).
Tungsten carbide cermet is normally has binder contents in the 6% to 16%
(by weight) range. Because tungsten carbide grains are metallurgic ally
bonded with the binder, there is no porosity at boundaries between the
binder and grains of tungsten carbide, and the cermet are less susceptible to
damage by shear and shock, table 3-2 shown the tungsten carbide properties.

Table 3-2 : Comparison Of Diamond, PDC, And Tungsten Carbide Materials.

Hard-facing materials are designed to provide wear resistance (abrasion,

erosion, and impact) for the bit. To be effective, hard facing must be resistant
to loss of material by flaking, chipping, and bond failure with the bit. Hard
facing provides wear protection on the lower area of all roller cone bit legs
and as a cutting structure material on milled tooth bits.
5. Polycrystalline Diamond Compact (PDC) bit
design
Polycrystalline diamond materials, for use in polycrystalline diamond
compact (PDC) bits, are one of the most important material advances for oil
drilling tools in recent years. Fixed-head bits rotate as one piece and contain
no separately moving parts. When fixed-head bits use PDC cutters, they are
commonly called PDC bits. Since their first production in 1976, the
popularity of bits using PDC cutters has grown steadily, and they are nearly
as common as roller-cone bits in many drilling applications.

5.1. Factors affecting bit design and performance

The considerations primarily influence bit design and performance are the
mechanical design parameters, materials, hydraulic conditions, and the
properties of the rock being drilled.

5.2. Geometric parameters of PDC bit design

Geometric considerations include bit shape or profile, which is predicated
based on the cutter geometry, cutter, placements, cutter density, hydraulic
requirements, and the abrasiveness and strength of the formations to be
drilled and well geometry. Each of these factors must be considered on an
application-to-application basis to ensure achievement of rate of penetration
(ROP) goals during cooling, cleaning the bit, and removing cuttings
efficiently. During design, all factors are considered simultaneously.
 5.3. Cutting structure characteristics
Cutting structures must provide adequate bottom hole coverage to address
formation hardness, abrasiveness, and potential vibrations and to satisfy
productive needs.

Early (the 1970s) PDC bits incorporated elementary designs without

waterways or carefully engineered provisions for cleaning and cooling. By
the late 1980s, PDC technology advanced rapidly as the result of a new
understanding of bit vibrations and their influence on productivity. Today,
cutting structures are recognized as the principal determinant of force
balancing for bits and for ROP during drilling.

5.3.1. Cutting mechanics

The method in which rock fails is important in bit design and selection.
Formation failure occurs in two modes:

Brittle failure.
Plastic failure.
The mode in which a formation fails depends on rock strength, which is a
function of composition and such down hole conditions as:
Depth
Pressure
Temperature
Formation failure can be depicted with stress-strain curves shown in figure
4-1. Stress, applied force per unit area, can be:
Tensile
 Compressive
Torsional
Shear
Strain is the deformation caused by the applied force. Under brittle failure,
the formation fails with very little or no deformation. For plastic failure, the
formation deforms elastically until it yields, followed by plastic deformation
until rupture.

Figure 4-7: Formation failure from stress and strain.

PDC bits drill primarily by shearing. The vertical penetrating force from
applied drill collar weight and horizontal force from the rotary table is
transmitted into the cutters as shown in figure 4-2. The resultant force
defines a plane of thrust for the cutter. Cuttings are then sheared off at an
initial angle relative to the plane of thrust, which is dependent on rock
strength.
 Figure 4-8:Shear and thrust on a cutter.

Formations that are drillable with PDC bits fail in shear rather than
compressive stress typified by the crushing and gouging action of roller-
cone bits. Thus, PDC bits are designed primarily to drill by shearing. In
shear, the energy required to reach the plastic limit for rupture is
significantly less than by the compressive stress. PDC bits require less
weight on bit (WOB) than roller-cone bits.

Thermally stable PDC cutters are designed to plow or grind harder

formations, because of their thermal stability and wear resistance. This
grinding action breaks cementing materials bonding individual grains of
rock.
 5.4. Cutters
Cutters are expected to endure throughout the life of a bit. To perform well,
they must receive both structural support and efficient orientation from bit
body features. Their orientation must be such that only compressive forces
load them during operation. To prevent loss, brazing material that has
adequate structural capabilities and has been properly deposited during
manufacturing must retain cutters.

Cutters are strategically placed on a bit face to ensure complete bottom hole
coverage. Cutter density refers to the number of cutters used in a particular
bit design. PDC bit cutter density is a function of profile shape and length
and of cutter size, type, and quantity. If there is a redundancy of cutters, it
generally increases from the center of the bit to the outer radii because of
increasing requirements for work as the radial distance from the bit
centerline increases. Cutters nearer to the gauge must travel farther and
faster and remove more rock than cutters near the centerline. Regional cutter
density can be examined by rotating each cutters placement onto a single
radial plane.

Reducing the number of cutters on a bit faces yields the following results:

The depth of cut increases.

ROP increases.
Torque increases.
Bit life is shortened.

Increasing cutter density yields:

 Decrease in ROP.
Decrease in cutting structure cleaning efficiency.
Increase in bit life.

Cutter density has been increased in the outward radial direction from the
bit centerline for the bit depicted in. Note that planar cutter strike pattern
inscribes an image of bit profile.

5.4.1. Components of PDC cutter

PDC cutters are made up of a working component, the diamond table, and a
supporting component called the substrate.

Substrates are a composite material made up of tungsten carbide grains

bonded by a metallic binder. This material bonds efficiently with diamond
tables, but is very hard and capable of impeding erosive damage to a
working cutter, As shown in figure 4-3.
 Figure 4-9:Typical geometries between diamond tables and substrates.

The shape of a diamond table is governed by two design objectives. It must

include the highest possible diamond volume and total diamond availability
to its working features. It must also ensure the lowest possible stress level
within the diamond table and at the substrate bond, As shown in figure 4-4.

Figure 4-10:Cutter section showing diamond table and interface style.

 5.4.2. Cutter optimization
To achieve cutter durability and reliable bonds between diamond tables and
substrates as shown in figure 4-5, design engineers use a variety of
application-specific cutter options. These include:

Cutter diameter options between 6 and 22 mm.

Optimized total diamond volumes in diamond table designs.
Special diamond table blends.
A variety of nonplanar interface shapes that increase bond area and
reduce internal stresses between the diamond table and substrate.
A variety of external cutter geometries designed to improve
performance in particular drilling environments.

Figure 4-11:Examples of special-purpose and extreme service cutters.

Certain cutter designs incorporate more than one diamond table. The
interface for the primary diamond table is engineered to reduce stress. A
secondary diamond table is located in the high-abrasion area on the ground-
engaging side of the cutter. This two-tier arrangement protects the substrate
from abrasion without compromising structural capability to support the
diamond table.

6. Selecting a drill bit

There is more than one method to make a choice and select the bit type
which satiable for a specific case, these methods are based on both technical
and economic side.
Some important rules to help guide in drilling bit selection are discussed
below:

6.1. Rules of thumb for bit selection

Shale has a better drilling response to drill speed.

Limestone has a better drilling response to bit weight.
Bits with roller bearings can be run at a higher speed than bits with
journal bearings.
Bits with sealed bearings have a longer life than bits with open
bearings.
Bits with journal bearings can be run at higher weights than bits with
roller bearings.
Diamond product bits can run at higher speeds than three-cone bits.
Bits with high offset may wear more on gauge.
Cost-per-foot analysis can help you decide which bit to use.
Examination of dulls can also help you decide which bit to use.

6.2. Tripping can ruin a new bit

Make the bit up to proper torque.

Hoist and lower the bit slowly through ledges and doglegs.
Hoist and lower the bit slowly at liner tops.
Avoid sudden stops. Drillpipe stretch can cause a bit to hit the hole
bottom.
If reaming is required, use a light weight and low speed.
6.3. Establish a bottom hole pattern

Rotate the bit and circulate mud when approaching bottom. This will
prevent plugged nozzles and clear out fill.
Lightly tag bottom with low speed.
Gradually increase speed and then gradually increase weight.

6.4. Use a drill-off test to select best weight on bit

(WOB) and speed

Select speed.
Select bit weight. Depending on bit selected, refer to appropriate
manufacturers recommended maximum speed and WOB.
Lock brake.
Record drill-off time for 5,000-lbm increments of weight indicator
decrease.
Repeat this procedure for different speeds.
Drill at the weight and speed that give the fastest drill-off time.

6.5. The bit is not always to blame for low ROP

Mud weight may be too high with respect to formation pressure.

Mud solids may need to be controlled.
Pump pressure or pump volume may be too low.
Formation hardness may have increased.
Speed and weight may not be the best for bit type and formation. Use
drill-off test.
Bit may not have adequate stabilization.
 Bit may be too hard for the formation.

6.6. Drill bit economics

Regardless of how good a new product or method may be to a drilling
operation, the result is always measured in terms of cost per foot or meter.
Lowest cost per foot indicates to drilling engineers and supervisors which
products to use most advantageously in each situation. Reduced costs lead
directly to higher profits or the difference between profit and loss.

For those in administration, engineering, manufacturing, and sales, cost

calculations are used to evaluate the effectiveness of any product or method,
new or old. Because drilling costs are so important, everyone involved
should know how to make a few simple cost calculations.

For example, the cost of a polycrystalline diamond compact (PDC) bit can
be up to 20 times the cost of a milled-tooth bit and up to 4 times the cost of a
tungsten carbide insert (TCI) bit. The choice of a PDC bit, a milled-tooth bit,
or an insert roller-cone bit must be economically justified by its
performance. Occasionally, this performance justification is accomplished
by simply staying in the hole longer. In such cases, the benefits of using it
are intangible.

The main reason for using a bit is that it saves money on a cost-per-foot
basis. To be economical, a PDC bit must make up for its additional cost by
either drilling faster or staying in the hole longer. Because the bottom line on
drilling costs is dollars and cents, bit performance is based on the cost of
drilling each foot of hole.

Breakeven analysis of a bit is the most important aspect of an economic

evaluation. A breakeven analysis is necessary to determine whether the
added bit cost can be justified for a particular application.

The breakeven point for a bit is simply the footage and hours needed to
equal the cost-per-foot that would be obtained on a particular well if the bit
were not used. To break even, a good offset well must be used for
comparative purposes.

7. Conclusions
Rotary drilling uses two types of drill bits, roller cone bits and fixed
cutter bits.

There are basically three types of drilling bit:

1. Drag Bits
2. Roller Cone Bits
3. Diamond Bits
Roller cone bits (or rock bits) are still the most common type of bit
used worldwide.

The considerations primarily influence bit design and performance are

the mechanical design parameters, materials, hydraulic conditions, and the
properties of the rock being drilled.
 Materials properties are a crucial aspect of a bit performance.
Components must be resistant to abrasive wear, erosion, and impact loading.

The eventual performance and longevity results for a bit take into
account several metallurgical characteristics, such as:
1. Heat treatment properties.
2. Weld ability.
3. The capacity to accept hard facing without damage.
4. Machinability

Cutters are expected to endure throughout the life of a bit.

Reducing the number of cutters on a bit faces yields the following
results:
1. The depth of cut increases.
2. ROP increases.
3. Torque increases.
4. Bit life is shortened.
8. References

1. Bentson, H.G., and Smith Intl. Inc. 1956. Roller Cone Bit Design. Los
Angeles, California: API Division of Production, Pacific Coast District.

2. Portwood, G., Boktor, B., Munger, R. et al. 2001.Development of Improved

Performance Roller Cone Bits for Middle Eastern Carbonate Drilling
Applications. Presented at the SPE/IADC Middle East Drilling Technology
Conference, Bahrain, 22-24 October.

3. Kerr, Callin Joe, 1988. PDC Drill Bit Design and Field Application
Evolution, Journal of Petroleum Technology Volume 40, Number 3. 14075-
PA.