Summary It is well-known that cutter layout on a polycrystalline-diamond compact (PDC) bit plays a key role in bit stability and drilling efficiency. In today's PDC bit, cutters are laid out according to two general principles: single set or track set. A single-set cutter layout is defined as having no cutters at the same radial or axial position after cutters are rotationally projected into a radial plane passing through the bit axis (this is referred to as bit profile in the industry). On the other hand, a track-set layout is defined as having at least two cutters at the same radial and axial positions on a bit profile but on different blades. In most track-set designs, cutters on primary blades are single set, and cutters on minor blades are redundant to those on primary blades. An extreme version of track set is called track loc, in which there is only one primary blade and cutters on all other blades are redundant to those on the primary blade (Weaver and Clayton 1993). Figs. 1a through 1c depict single set, track set, and track loc, respectively, demonstrating that the major difference is the engagement area or width of indentation of cutters while drilling. The single-set cutter has the smallest indentation width, and the track-loc cutter has the largest indentation width. According to laboratory and field tests, a PDC bit with single-set cutters drills much more efficiently than a PDC bit with track-set cutters (Besson et al. 2000). On the other hand, a PDC bit with track-loc cutters is extremely stable but extremely inefficient. Bit stability may be enhanced by laying out the cutters so that the bit lateral forces are balanced or minimized. This is called a "force-balanced" PDC bit (Glowka 1989; Behr et al. 1993; Clayton et al. 2005). In some applications, cutters are laid out so that a large lateral imbalance force [as high as 15 to 20% of weight on bit (WOB)] is created and directed toward a so-called low-friction gauge pad, which is on one side of the bit. The bit is called an "anti-whirl" PDC bit (Brett et al. 1989; Warren et al. 1990). Successful field applications of this technology have been reported (Warren et al. 1990). In this paper, it is found that the force-balanced condition of a PDC bit with single-set cutters may be violated during transit-formation drilling. A new cutter layout procedure is proposed, which not only ensures the force-balanced condition during transit drilling but also significantly improves drilling efficiency. The concepts developed in the paper are first verified by laboratory tests of a core PDC head and then a full PDC bit. Two case studies of the new bits in drilling through hard and transit formations are detailed in the paper.

Summary Almost all previous cutter-force models assumed that cutting force was proportional to cutting area. Cutting-area-based single-cutter-force models were extensively used in polycrystalline-diamond-compact (PDC) -bit design optimization. This paper explains why cutting-area-based bit models failed to predict bit forces. A new cutter force model and a new bit model were developed and are discussed in the paper. In the new cutter force model, cutting force is a function of the shape of the cutting area. A common force model is developed for three types of cutting shapes. In the new bit model, 3D rock chips created in front of cutting face are modeled, meshed, and removed from the hole bottom by updating the hole bottom at each timestep. To validate the new model, four different PDC bits were designed, manufactured, and laboratory-tested under controlled conditions. Details from laboratory testing and field-test results are presented.

Almost all previous cutter force models assumed that cutting force was proportional to cutting area. Cutting-area-based single cutter force models have been extensively used in polycrystalline diamond compact (PDC) bit design optimization. This paper explains why cutting-area-based bit models failed to predict bit forces. A new cutter force model and a new bit model have been developed and are discussed in the paper. In the new cutter force model, cutting force is a function of the shape of the cutting area. Three types of cutting shapes are respectively modeled. In the new bit model, three-dimensional (3D) rock chips created in front of cutting face are modeled, meshed, and removed from the hole bottom by updating the hole bottom at each time step. To validate the new model, six different PDC bits were designed, manufactured, lab tested under controlled conditions, and field tested. Details from laboratory testing and field-test results are presented.

This paper presents a theory on layout PDC cutters in force-balanced groups. A group of cutters consists of two or three single-set cutters, which is able to efficiently remove a ring of rock. By carefully selecting the order of layout cutter groups, a new feature of a PDC bit is obtained: any three or four consecutive cutters on a bit profile may form a force-balanced cutter group, which ensures the efficient removal of any ring of rock. The concepts are verified by a core PDC bit and by a fullscale PDC bit in laboratory tests. Two field applications are provided in the paper to further validate the theory.

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