Numerical Simulation and Field Test of PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Abstract

The cutter structure and layout scheme of PDC (Polycrystalline Diamond Compact) bits are important factors in improving efficiency. To further improve the drilling efficiency of PDC bits, axe, triangular prism, and cylindrical PDC cutters were used as research objects. Based on the measured granite data, a finite element model of non-homogeneous granite was established and verified by uniaxial compression simulation. The rock-breaking process of different cutter combination schemes was compared using the finite element method, and the parameters in the best scheme were optimized using the Box-Behnken response surface method. The results show that the constructed model of non-homogeneous granite is consistent with the stress-strain relationship of real granite and is reliable. The axe PDC cutter is more aggressive than the other two cutters and is more suitable for the front row of the bit blade tooth arrangement, while the triangular prism cutter is the second most aggressive and is suitable for the rear row of tooth arrangement, and the best combination scheme is the front row of axe cutter and the rear row of triangular prism cutter arranged alternately with the axe cutter. The optimal transverse and longitudinal distances of the optimized triangular prism cutter from the front axe cutter are 10mm and 7mm, and the optimal transverse and longitudinal distances of the rear axe cutter from the front cutter are 10.06mm and 7mm. The drilling speed is more stable during drilling and the PDC bit with mixed tooth arrangement has 16.8% and 16.6% higher rate of penetration(ROP) compared with the bit with single axe cutter and triangular prism cutter, and the drilling speed is more stable during working, which can effectively improve the rock breaking efficiency of the PDC bit. The field application proves that the bit with mixed cutter arrangement is easier to break the complex formations, with more stable ROP and better efficiency. The study can provide theoretical support for the cutter layout of the PDC bit.