Contents

Diamond Bit § Bit Components

Components &Technology § Technology
§ Dynamics

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

PDC Bit Structure PDC Face View

Blade

API Connection
Shank

Breaker Slot Junk Slot

Identification Slot
Weld
Blank Nozzle
Crown Chamfer Cutters
Matrix Bit Body
Gauge Pad
Nozzle
Cutters

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

1
 Diamond Bit Materials Steel Blank
§ Steel “skeleton” of a
§ Matrix Body matrix body bit
§ Manufactured with a cast, graphite mold § The tungsten carbide
§ Bit body made up of tungsten carbide matrix powder matrix is cast around
§ Bonded together with a copper alloy binder the blank
§ Very resistant to erosion and abrasion § Provides for
attachment of the
shank
§ Soft, ductile steel
(1018)

Blank

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Shank Diamond Bit Materials

§ Steel Body
§ The API regular connection § Steel body design uses a steel body welded to separate shank
(two piece design)
§ Breaker slots
§ Milled from bar stock steel
§ Identification slots
§ High alloy, heat treated steel
(4140)

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

2
 Nozzles Diamond Cutting Structures
§ Sintered tungsten carbide

MSP § Standard size is the “SP” (Single

Piece)
Natural Diamond
PDC
SP § Additional size developed for smaller
bits is the “MSP” (Micro SP)

TSP Impregnated
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Polycrystalline Diamond PDC Cutter Properties

Compact (PDC)
§ Diamond Table
§ Man-Made Diamonds
§ Determines abrasion and impact resistance
Diamond Table § A natural diamond is a single crystal, the term
polycrystalline means many crystals
Tungsten Carbide
Substrate § Diamond / Carbide Interface
45º Edge Chamfer § Affects impact resistance

§ Edge Geometry
§ Primarily influences impact resistance
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

3
 PDC Cutter Sizes PDC Cutter Size vs. Bit Size

0.866” (22 mm) Smith Solid Preferred Light Acceptable

8mm Cutter
0.750” (19 mm) HCC, Smith, SecDBS, Hycalog
13mm Cutter
0.625” (16 mm) HCC, Smith, SecDBS, Hycalog
16mm Cutter
0.529” (13.3 mm) HCC, Smith, SecDBS, Hycalog
19mm Cutter
0.323” (8.2 mm) HCC, Smith, SecDBS, Hycalog <5” 5¾” - 6¾” 6¾” - 10” 10” - 14¾” >14¾”

0.25” (6 mm) Smith Bit Size Range

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

PDC Cutter Size vs. ROP Genesis XT Cutter Development

Max. ROP (ft/hr)
Cutter Size § Boring Mill
100 RPM 180 RPM A
B

0.323” (8.2 mm) 81 146

0.529” (13.3 mm) 133 240
§ Mixed Cutter Test
0.750” (19.1 mm) 188 338

0.323” (8.2 mm) 0.162” x 100 RPM x 5 = 81 ft/hr § Finite Element Analysis
5.0

0.529” (13.3 mm) 0.265” x 100 RPM x 5 = 133 ft/hr

4.0

3.0

§ PDC Wear Modeling

2.0

1.0

0.0
-5.0 -4.0 - 3 . 0 -2.0 -1.0 0.0 1.0 2.0 3.0 4.0 5.0
-1.0

-2.0

0.750” (19 mm) 0.375” x 100 RPM x 5 = 188 ft/hr -3.0

-4.0

-5.0

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

4
 Genesis XT
Genesis XT
Lab Boring Mill Test
Zenith Series cutters are four times more
Layered Technology abrasion-resistant than older PDC
cutters.
§ Abrasion resistant surface
Genesis XT Zenith Series
§ Tough diamond backing

Relative Wear Resistance

§ Stress-engineered interface Genesis
2003

Genesis
Genesis 2002
Black Diamond 2001

Gold Series

Conventional Layered ALC

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Genesis Foundation Polished PDC Cutters

“Black Ice”
Ice”
D4 - Modesto
§ Coefficient of Friction on Diamond
D3 - Niagara Face is Reduced by Reducing
A1 A2 A3 D2 D3 D4 Surface Roughness
(AXSYM) ( Manhattan) D2 - Bargo
( Alba) ( Bargo) ( Niagara) (Modesto)

A1 - AXSYM D1 - Gotham § Conventional PDC

§ 20 -30 m in RMS
A2 - Manhattan

A3 - Alba
§ Polished PDC
§ 0.3 - 0.7 m in RMS
A Abrasive Wear Fracture Dominated D
Dominated Applications Applications
20

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

5
 Polished Cutters Genesis Nomenclature
§ HC XYY
§ HC = HCC Genesis
§ HC = Genesis Rotary
§ HCR = Genesis Rotary Steerable
§ HCM = Genesis Motor Steerable

Built-Up Edge § X = Cutter Size

§ 6 = 19mm
§ 5 = 16mm
§ 4 = 13mm
§ 3 = 8mm
HC 4 08
§ YY = Blade Count
e
Lin Siz
e nt
uc
t er ou
§ No Prefixes - or Suffixes od utt eC
Polished Cutter r C d
P Bla
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Impreg Product Line Diamonds used in Impreg Bits

Conventional Impreg
§ Synthetic diamonds

§ Commonly called ‘Grit’

§ High strength and

thermal stability

§ Typical size 0.025”

(25/35 Mesh)

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

6
 Types of Segments: HPI Types of Segments: LPI

§ HPI - High Pressure Infiltration § LPI - Low Pressure Infiltration

§ Also known as hot pressed or ring segments § Segment formed during bit casting process
§ Segments formed prior to bit casting § Very wear resistant matrix
§ Suitable for the most abrasive formations

S280
S279
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Hedgehog Segments Impregnated Application

§ LPI - Low Pressure Infiltration § Typically used for the hardest formations
§ Segment formed during bit casting process
§ Matrix formulations designed to suit application
§ Often compared to a grinding wheel
§ R10 - soft § Traditionally, the formation to be drilled must
§ R30 - standard possess some abrasiveness
§ R60 - hard
§ However, HH has been used successfully in
carbonate formations.
§ High rotation speed will maximize performance

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

7
 Introduction to Bit Profiles
Diamond Design § The term “profile” or “crown profile” refers to the
distinctive shape of the bit head when viewed from the
Technology side

§ A variety of profile shapes and lengths are used to

Profiles, layouts, hydraulic design optimize bit performance depending on the bit type and
and cutting mechanics application

§ The basic objective of any profile is to optimize bit

stabilization and wear as well as achieve well bore
trajectory objectives

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

The PDC Bit Profile PDC Profile Types

§ Bit profile and cutter layout are
closely related. Each cutter
Bit Center Line

layout is compromise between

the following:
Gauge 0,0,0 Point
§ Maximum number of cutters
Length (longer bit life)
§ Lowest blade count (better
adius
Shoul
der R
Nose Location
hydraulics, ROP)
Shoulder Cone Angle
§ Shortest possible profile
Nose
Radius
(better bit stability / cleaning) Short Parabolic Shallow Cone Long Parabolic
Cone
Nose

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

8
 Cutter Orientation-
Orientation -
Single Cutter Forces
Back Rake
20º Backrake 30º Backrake
15º Backrake
Depth of Cut

F Torque Fnormal
Fwob Fnormal
Fwob
Fside
Fwob
Resultant Load Fside

§ The back rake determines the aggressiveness of the

cutter § A cutter will see a different magnitude & direction of forces
§ Measuring from vertical, the less the angle of back
dependent on it’s location on the bit profile.
rake, the more aggressive the cut
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Force Balancing

§ Individual cutter force vectors

5.0

4.0
are summed to create total
side and torque imbalance
3.0

2.0
Cutter Layouts
forces 1.0

§ The adjustment of cutter -5.0 -4.0 -3.0 -2.0 -1.0

0.0
0.0 1.0 2.0 3.0 4.0 5.0
-1.0
positions to achieve a desired -2.0

imbalance force percentage -3.0

§ The percentage is a factor of -4.0

the WOB -5.0

Side (Radial)
Torque (Tangential)
Resultant (Total Imbalance)

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

9
 Spiral Layouts Kerfing Layout

§ Special adaptation of the

spiral layout

§ Cutters on secondary
blades have the same radial
position as cutters on the
primary blades
Forward Spiral Reverse Spiral

§ Spiral starts from the geometric center of the bit

§ Each cutter has its own unique radial position (single set)
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

High Imbalance Cutter Layout Summary

§ Forward or reverse spiral defined as before
Forward Spiral
§ Cutters are laid out so that a high imbalance force is generated
Single Set
§ Used to be known as “Antiwhirl”
§ A “low friction area” is created Reverse Spiral
Low Imbalance

Recessed Kerfing
Imbalance Cutter Area
Force

Recessed
Cutters
Forward Spiral
High Imbalance
(Anti-whirl)
Single Set
Reverse Spiral
Low Friction Area

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

10
 Cutting Efficiency - Backrake
20º Backrake 30º Backrake
15º Backrake

Cutter Mechanics

15º Backrake 20º Backrake 30º Backrake

§ Generally, smaller backrake angles require less weight and torque

§ The magnitude of the effect depends on rock strength

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Decreasing Backrake Increases

Cutter Edge Geometry
Efficiency
Medium Shale, C o = 3 kpsi § Smaller chamfer size provides
more efficient cutting
Specific Energy vs. Penetration Rate mechanism
0.016 in. x 45 o , Mancos, 3 kpsi
100,000
15 deg § Larger size provides more
90,000 20 deg durability - depends on rock
80,000 30 deg strength
Specific Energy (psi)

70,000 40 deg Specific Energy vs. Penetration Rate

o

§ Compromise between sharp

G445XL, 1 0 BR, Mancos, 3 kpsi
90,000
60,000 0.005 in.
80,000
50,000 efficient cutting and durability 70,000
0.010 in.
0.016 in.

Specific Energy (psi)

60,000 0.050 in.
40,000
30,000 § Effect dependent on rock 50,000

40,000

20,000
strength 30,000

Increasing WOB 20,000

10,000 10,000

0
0 0 20 40 60 80 100 120 140
Penetration Rate (ft/hr)
0 20 40 60 80 100 120 140
Penetration Rate (ft/hr)

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

11
 PDCWear Predictions:
Can we just use small chamfers
New vs. Worn
and 15º
15 º BR?
Even cooling
Full carbide support Specific Energy vs. Wear
120 RPM 084 G445XL Variants
§ Based on our current technology, 160,000
the answer is NO 15 deg BR 30% Worn
140,000 20 deg BR

Specific Energy (psi)

30 deg BR
120,000
40 deg BR
§ In part, because durability would 100,000

suffer 80,000 New

Condition
60,000

§ Also, because low backrakes 40,000

affect wearflat development 20,000

0
§ For a given wear state, lower 0 100 200 300 400 500 600 700
backrakes yield bigger wearflats Distance Drilled (ft)

Low backrakes are more efficient in the “new” state

25º 15º 10º
As bits wear they can become less efficient
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Hydraulic Efficiency

§ Cuttings Removal (“Cleaning”)

Hydraulic Design § The effectiveness of each layout is determined
through laboratory tests in sticky shale under fixed
conditions
§ Maximum ROP without balling

§ Cutter Cooling
§ Keep the velocity of drilling fluid within an
acceptable range at the face of each cutter along
each blade

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

12
 CFD - Computational Fluid Particle Residence Time Simulation
Dynamics
Maximize ROP Minimize Erosion
§ Minimize Particle
§ Control Fluid Velocity
Residence Time
§ Balanced Flow
§ Minimize Re-circulation

Poor evacuation -- cuttings are Good cuttings evacuation

forced to center of bit

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Balanced Flow

Flow balance for original nozzle Flow balance for optimized

orientation configuration
Bit Dynamics
%Flow/%Cuttings Comparision %Flow/%Cuttings Comparision
%Flow/%Cuttings Comparision %Flow/%Cuttings Comparision
2.5
2.5
2.0
2.0
1.4
1.4
1.2
1.2
Vibration & Stability
%Flow/%Cuttings

%Flow/%Cuttings

1.5 1.0
%Flow/%Cuttings

%Flow/%Cuttings

1.5 1.0
1.0 0.8
1.0 0.8
0.5 0.6
0.5 0.6
0.0 0.4
0.0 0.4
-0.5 0.2
-0.5 0.2
-1.0 0.0
-1.0 1 2 3 4 5 6 0.0 1 2 3 4 5 6
1 2 3 4 5 6 1 2 3 4 5 6
Slot # Slot #
Slot # Slot #

Reverse
Flow
© 2002 Baker Hughes
All rights reserved
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

13
 Types of Vibration Another “Stick slip”
slip” example

§ Bit Bounce
§ Axial vibration

§ Stick
Stick--Slip
§ Torsional vibration

§ Whirl
§ Lateral vibration
§ Resistance to whirl is called “lateral stability”

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

What Is “Lateral Instability”

Instability” Bit Whirl ...
or “Whirl
Whirl””?
Very “unstable” bit “Stable” High Imbalance bit
§ A form of lateral vibration that (G417) (HC605)
PDC bits tend to generate,
commonly called bit whirl

§ Individual blades “gear”

around the hole in a direction
opposite the bit rotation
§ The bit rotates clockwise about
its axis (looking down), but
moves around the hole in a
counterclockwise direction Drilling Lab Video slowed down - actual RPM 120

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

14
 Instability Affects Performance System Effects on Bit Stability
§ Stability Increases Durability § Bit Performance Depends on BHA
Performance
§ Greatly Influences ROP
§ Once Cutters Sustain Damage, the Bit Slows Dramatically § Drill collars are “unbalanced” and tend to
vibrate when rotated (like an unbalanced
§ Damage to Shoulder Cutters Feeds High, Erratic Torque car tyre)

§ BHA design and operation controls the

severity of this vibration Video of a drill collar imbalance test
• 6.25” collar
§ The resulting BHA vibration loads the bit • 140 RPM
• Power swivel on top, custom
unevenly bearing assembly in rotary table

Abrasion Damage Impact Damage

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

What Is “Lateral Stability?”

Stability?” Lateral Stability Components
§ Consists of Two Interrelated Parts:
The Ability To Resist Whirl § Primary stability
§ The tendency of a bit to drill “smoothly”
§ A Key Component of Durability
§ Controlled by cutter layout
§ Controls impact loading on PDC cutters
§ Prior to Genesis this was all we considered
§ Best case: mild vibration
§ Vibration causes minor chippage and accelerates wearflat § Secondary stability
development
§ The magnitude of vibration when unstable
§ Worst case: severe vibration
§ Intense dynamic loads cause catastrophic impact damage § This affects the ability to resist drilling system instability
§ Try to limit the effects of this instability

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

15
 Primary Stability

Making Genesis Bits Stable – How? Low Imbalance Single Set

Primary Stability: Controlled by Cutter Layout § Cutters are placed in spiral patterns from the center
§ Genesis uses high and low imbalance strategies outward
§ High imbalance § Forward spiral: Clockwise in face view
§ Improvement over “Anti -Whirl” § Reverse spiral: Counter-clockwise in face view

§ Low imbalance
§ Spiral
§ Kerfing
§ Two step

Forward Reverse
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Primary Stability Primary Stability

Low Imbalance Single Set ... Low Imbalance Strengths &

Weaknesses
How Does It Work?
§ A low imbalance force is the goal § Cutting structures can be efficient
§ If the imbalance is low, the tendency to deviate from “ideal § Doesn’t rely on rubbing or high side load for stability
motion” (stable, on-center drilling) is minimized
Maximum cutter density in nose and shoulder helps prevent ring-out
§ Can use maximum cutter density to provide
durability
BUT

§ Not able to overcome system instability

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

16
 Primary Stability Primary Stability
Low Imbalance Kerfing Kerfing ...

§ How Does It Work?

§ Forward and reverse spiral defined as before
§ Large kerfs (grooves) in bottom hole pattern help
§ Cutters on secondary blades have the same
limit lateral motion
radial positions as those on primary blades
Identical radial positions create large kerfs in bottom hole pattern

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Primary Stability Primary Stability

Kerfing - Strengths & Weaknesses High Imbalance Single Set
§ Cutter density can be high to improve durability
§ Forward and reverse spiral defined as before
§ The restoring forces from the kerfs provide some ability to
overcome system instability § Cutters are laid out so that a high imbalance force is
BUT generated
§ Relies on kerfs to provide stability
§ A “low friction area” is created
§ Weak formations provide very small restoring force
§ This may limit effectiveness in these formations § Shoulder cutters are recessed Imbalance
on blades near the imbalance force Force
§ Cutting structures tend to be inefficient
§ Secondary blades have low depths of cut due to trailing § This provides a “low friction” area
primary blades that “slides ” instead of cutting
§ Low depth of cut decreases efficiency
© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

17
 Primary Stability
High Imbalance ... Secondary Stability:
Controlling Vibration Severity
§ How Does It Work?
§ Genesis bits are designed to limit the severity of vibration when
§ A high imbalance force is desired
§ Design Guidelines call for approximately 15 % of applied WOB drilling in an unstable mode
§ Imbalance force keeps the low friction area in contact with the hole § This helps protect cutters from impacts
§ The recessed cutters in the low friction area prevent blades from
“grabbing” the hole and feeding whirl § Accomplished through chordal drop management
§ Gauge pads are wider
§ Strengths and Weaknesses? § Spiral gauge pads are used on low blade counts
§ The concept can provide very stable bits
§ The “recessed cutter area” causes shoulder durability issues § External features are used to protect cutters
§ The high imbalance force can help overcome BHA instability § Lateral Movement Mitigator (LMM) is used on all bits
§ Wear Knots or BRUTE inserts are optional...

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

Secondary Stability Secondary Stability

Chordal Drop Management Lateral Movement Mitigator (LMM)
§ The bigger the drop, the more
severe the impacts § Formed by building up blade behind and around gauge
N=3 N=4
§ Wider gauge pads (optimized cutters
junk slot held “constant”) § Protects gauge & upper shoulder cutters from impact
N=5 N=6
§ Wide, spiral pads for 3 and 4 Stability Indicators vs. ROP
8.500 DP0123 (R0018) RADXC
30 30,000

blade designs 25 25,000

Specific Energy (psi)

MU Variation (%)
20 20,000

15 15,000

10 10,000

5 5,000

0 0
0 5 10 1 5 20 2 5 30 3 5 40 4 5 50
ROP (fph)

Stability Indicators vs. ROP

8.500 DP0188 (R0034) LMM050
30 30,000

25 25,000

Specific Energy (psi)

MU Variation (%)
20 20,000

15 15,000

10 10,000

5 5,000

0 0
0 5 10 1 5 20 2 5 30 35 40 45 50
ROP (fph)

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

18
 Secondary Stability
BRUTE Inserts Dynamics Summary

§ Acronym for “Backups that are Radially

Primary Stability Secondary Stability
Unaggressive and Tangentially Efficient”
§ The ability of a bit to drill § The magnitude of vibration
§ A thick diamond table cutter is embedded in smoothly when unstable
a wear knot and oriented so that it can cut § Controlled by chordal drop
§ Inter-related with system
tangentially, but not radially (sideways) management (standard)
stability
§ Polished diamond provides a “low friction
wear knot” § Primarily controlled by § Also controlled by external
§ Orientation allows BRUTE to do work if cutter layout features:
leading cutter is damaged § LMM (standard)
§ Recessed 0.100” § Wear Knots / Clouds (option)
§ BRUTES (option)

© 2005 Baker Hughes All rights reserved © 2005 Baker Hughes All rights reserved

No Break

Next Topic:
Tricone Technology

© 2005 Baker Hughes All rights reserved

19