SPE/IADC 91840

New Bit Design, Cutter Technology Extend PDC Applications to Hard Rock Drilling
Robert Clayton, Shilin Chen, and Guy Lefort, HES-Security DBS
Copyright 2005, SPE/IADC Drilling Conference
This paper was prepared for presentation at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 23-25 February 2005.
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Abstract
An advanced series of PDC drill bits incorporating a new
highly abrasion-resistant PDC cutter has extended effective
PDC bit application to hard rock drilling. In direct offset
comparisons, the advanced series of PDC bits fitted with the
new cutters delivered significant increases in footage drilled
and rate of penetration.
To achieve an optimum match in drilling efficiency and bit
life to lower costs and mitigate risk in hard rock environments,
the series is designed using a combination of advanced
modeling capabilities and sophisticated analytical tools. These
tools allow the designs to be "customized" for specific
applications, optimizing cutting efficiency and durability
according to specific rock properties and drilling parameters.
A transitional drilling model simulation allows evaluation of
how cutting forces are affected during transitional drilling,
common in hard rock environments. The bit design is
globally balanced to optimize axial, lateral, and torsional
forces, and can be modified by adjusting features such as
profile shape, cutter rake angles, impact arrestors, and cutter
type, to optimize bit performance when drilling in hard and
transitional environments.
In addition, recognition of a third dimension of PDC
performance Thermal Mechanical Integrity (TMI) -- has
lead to development of a new PDC cutter that provides 13.5
times the abrasion resistance of the industry standard, without
sacrificing impact resistance. This improved understanding of
PDC cutter failure provides a different way of looking at the
traditional characteristics of abrasion and impact, enabling
cutter durability to be optimized in both abrasive and hard,
inter-bedded formations.
The paper discusses the science behind the advanced series
of bits, including the impact of TMI on cutter performance.
New laboratory capabilities and testing results are described,

and actual field case histories presented to demonstrate

performance improvements of these PDC bits in hard rock
applications.
Introduction
One of the greatest challenges that any PDC bit manufacturer
faces today is the extension of PDC bit application into hard
rock drilling, where impact damage, heat damage and abrasive
wear of PDC cutters limits performance. Research and
development have been focused on better understanding of
cutter/formation interaction, cutter performance, bit dynamics
and BHA dynamics.
Since the first modeling studies conducted by Sandia
Laboratories in the late 1980s, analysis of the interaction
between the cutting elements of a PDC drill bit and the
formation it is drilling has been widely investigated. One of
the predominant developments from these early investigations
was the first reliable kinematics cutter force and wear
prediction model. These models were helpful for bit
manufacturers to better understand the mechanism of
cutter/formation interaction and to design the cutter layout of a
PDC bit so load and wear of cutters over the bit face can be
balanced.
Perhaps the most significant advancements in
understanding how this interaction affects bit performance
were the result of research conducted by the Amoco Research
Center during the late 80s. 1 Laboratory tests demonstrated
that conventional PDC bits whirl backwards during drilling,
and backward whirl was a primary cause of PDC cutter
damage. This important finding led to extensive studies in bit
dynamics and drillstring dynamics. Bit dynamics models,
including BHA dynamics models were developed and were
able to repeat the backward whirl phenomenon under specific
conditions. However these dynamics models were rarely used
by bit manufacturers in the bit design process due to their
complexity and limited ability to consider the effects of cutter
layout on bit dynamics.
There were two design principles identified; namely, antiwhirl PDC bit design and force balanced PDC bit design. The
anti-whirl PDC bit design principle 1, 2 incorporated a specific
design concept, namely low friction gauge, to minimize the
effect of bit backward whirl. According to this design
principle, cutters were so arranged over the bit face so that a
net resultant radial force (around 12% of weight on bit) was
directed toward a specified portion of the bit with less friction.

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CLAYTON, SHILIN, LEFORT

Since introduction of anti-whirl technologies in the late

80s, PDC bit utilization has made significant inroads into
roller cone markets, but has consistently faltered when drilling
the traditionally more difficult insert roller cone applications,
such as hard rock. In these applications, where roller cone bits
suffer short bit life and slow ROP as well as risk loss of cones,
PDC bits typically suffer short life as a result of high impact
damage, large vibration and abrasion.
The force balanced PDC bit design principle 3 was
developed based on the understanding of PDC bit dynamics
and the mechanism of cutter/formation interaction. Unlike an
anti-whirl PDC bit, the cutters on a force balanced PDC bit
were arranged so that a net resultant radial force was
minimized or balanced. The use of tracking cutters, where
multiple cutters located within a groove, provided a restoring
force to keep the bit rotating around hole center. The design of
a force balanced PDC bit allows a higher density of cutters on
the gauge, which is usually required in hard formation drilling,
than does the anti-whirl PDC bit. The use of force balancing,
tracking cutters and asymmetrical spiraled blades improved bit
performance significantly, further expanding the range of
applications for PDC bits.
Recently, significant performance improvements have
been achieved with a new series of highly-engineered PDC bit
designs utilizing advanced cutter technology to expand the
range of PDC applications into hard rock drilling. This paper
describes several key concepts and features including global
balancing, energy balancing, transitional impact prediction
model, and the development of highly abrasion-resistant PDC
cutters based on an improved understanding of thermal cutter
failure mechanisms.
Improved Cutter/Rock Interaction Model
Advanced Cutter/Rock Interaction Model. In order to
accurately calculate the forces acting on a PDC bit, it is
necessary to have a model presenting the cutter/rock
interaction. 4-6 Such a model should be able to predict the
forces acting on a cutter, as well as the force distributions over
cutting area when the cutter is engaged with the formation.
Previous models used in either kinematics calculation or in
dynamics calculation considered only three summarized forces
on a cutter based on the engaged area: drag force, normal
force and side force. 7,8 Fig. 1. Such a model is no longer valid
with the introduction of PDC cutters with a chamfered
geometry, which significantly affects bit ROP and WOB/TOB
relationship. Furthermore, laboratory tests have found that the
orientation of PDC cutter relative to rock surface, defined by
back rake angle, side rake angle and helical motion, play a
significant role in the determination of cutting forces.
As shown in Fig. 2, a new cutter/rock interaction model is
developed in which the cutting edge is divided into three
surfaces: cutting face surface, chamfer surface and cylinder
surface. There are three forces acting on each surface, namely,
drag force, axial force and radial force. In order to accurately
calculate the engagement area of the cutter, each surface is
meshed into very small grids. In this way, the effects of cutter
orientation on the engagement area can be considered.
Depending on the cutting depth, forces on each surface may be
significantly different.

SPE/IADC 91840

Advanced cutter wear model. It is well known that cutter

wear depends on cutting force, relative speed, temperature,
cutter material properties and rock properties. Previous wear
models estimated only the wear flat without considering the
orientation of the wear flat, the actual diamond thickness, the
interface geometry of diamond layer and carbide, and abrasive
resistance.
With the new cutter/rock interaction model described
above, cutter wear can be considered three dimensionally and
all neglected factors in the previous model can be easily
considered. (Fig. 3).
Global Balancing Concept for PDC Bits
There are three forces acting on a bit: bit axial force, bit lateral
force and a bending moment. It has been believed that
balancing lateral force is very important to prevent whirl.
Previous concepts of PDC bit force balancing referred only to
lateral force balance. It was also believed that once lateral
force was balanced, bit bending moment was also balanced.
A further study on bit forces found that even a perfectly
force balanced bit may exhibit tilt motion caused by bending
moment. In fact, bit bending moment consists of two parts:
one contributed by lateral force and another contributed by
axial force distribution over bit face. Fig. 4 shows an example
of bending moment generated by uneven distribution of axial
forces over cutters.
Bit bending moment contributes not only to bit lateral
motion or whirl, but also to bit tilt motion, which has a
significant effect on bit directional control. Therefore, bending
moment balancing becomes equally important as lateral force
balancing. A PDC bit featured with both lateral force and
bending moment balanced is a "global force balanced" bit.
The design of a global force balanced PDC bit involves
adjusting the cutting structure to reduce the imbalance
numbers. The new series of bits are force balanced according
to a specific set of design criteria, which considers the
summation of cutter forces to a global lateral and axial bit
imbalance. The global lateral bit imbalance consists of the
total, radial, and drag imbalances.
Energy Balancing Concept for PDC Bits
The energy balanced concept was initially developed for roller
cone bits, where forces and rock removed by each cone
(cutter) were evenly distributed among cones. Significant
performance improvement of energy balanced roller cone bits
has been consistently observed in the field worldwide. 9
The development of an energy balanced PDC bit is based
on the fact that the amount of formation removed by each
cutter on a bit is different, and as a result, the force acting on
each cutter also differs. Furthermore, the number of cutters
differs from blade to blade, therefore, the forces acting on
each blade differ. In order to avoid overloading individual
cutters and blade, it is necessary to control the load
distributions over the cutters and blades.
An element of an efficiently running bit is a cutting
structure that evenly distributes work among the cutters during
normal drilling. Energy balancing accomplishes even
disribution by minimizing the change in work or force among
regions or zones of the cutting structure. By controlling the

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SPE/IADC 91840

NEW BIT DESIGN, CUTTER TECHNOLOGY EXTEND PDC APPLICATIONS TO HARD ROCK DRILLING

force distribution over blades and over cutters, energy

balancing reduces impact damage and uneven wear while
promoting improved ROP.
The design of an energy balanced PDC bit involves
analyzing the distribution of work and forces on a cutting
structure with the aim of controlling force distribution over
blades and cutters. As with force balancing, a specific set of
design criteria has been developed which considers the ratio of
the average change in cutter torque across zones, to the
average cutter torque over the entire region.
Transition Drilling Model
The Transition Drilling Model simulates a fixed cutter bit
drilling through a change in rock strength such as sandstone to
shale. This transitional drilling model simulation allows
evaluation of how cutting forces are affected during
transitional drilling, common in hard rock environments.
The program uses the new cutter/rock interaction model to
calculate the amount of torque per revolution each cutter
experiences through the transition layer (Fig. 4). The model
data is used in the design stage, providing the ability to easily
evaluate lateral, torsional, and axial cutter forces and work to
control impact damage, further enhancing cutter performance.
This technology gives the designer the capability to
evaluate how the cutting forces are affected when the bit is
drilling into a harder or softer rock. In effect, this technology
enables designers, during bit design phase, to identify trouble
zones where impact damage could occur while transition
drilling. Bit features such as profile shape, blade count, start of
secondary blades, cutter back rake, impact arrestor location,
can all be manipulated to improve the bits ability to drill
transitional formations. (Fig. 5).
Development of New Cutter Technology
In addition to advanced models and design tools, the new
series of bits incorporate advanced PDC cutters, developed as
a result of an improved understanding of cutter failure
mechanisms. Understanding a PDC cutters failure
characteristic is the key to understanding how to improve its
performance. Historically, abrasion and impact have been the
two characteristics observed and studied.
Abrasion refers to the mechanically generated wear that
occurs due to failure of the individual diamond crystals and/or
the diamond-to-diamond bonds within the diamond table. The
diamond failure can be a result of mechanical loading and/or
thermal degradation.
Impact wear is a mechanical failure that occurs when
forces are applied which overcome the strength of the bond
between diamond crystals and/or to the carbide of the PDC.
As a result of extensive research and development, a third
dimension of PDC cutter failure has been identified, Thermal
Mechanical Integrity (TMI). TMI failure is defined as loss
of diamond that occurs due to a combination of thermal
degradation and force, and is a measurement of the cutters
toughness as wear and thermal degradation occur.
This improved understanding of cutter failure has brought
about a different way of looking at the traditional
characteristics of abrasion and impact. Advanced testing
capabilities now enable optimization of cutter durability in
both abrasive and hard inter-bedded formations, and led to

development of a cutter more suitable for the tougher

environments of hard rock drilling. (Fig. 6).
Testing Capabilities. Finite Element Analysis (FEA),
acoustic and scanning electron microscopic (SEM) analysis,
and destructive testing (DT) are utilized to evaluate new
diamond and carbide materials, new manufacturing processes,
and new designs in order to optimize all performance aspects
of a new PDC cutter.
Finite Element Analysis (FEA) evaluates stresses that
occur between the diamond table and the carbide substrate as a
result of the differences in rate of thermal expansion between
the two materials. Significant changes in temperature can
occur during manufacturing or due to drilling temperatures
down hole. FEA images allow the residual stresses to be
analyzed under different parameters. (Fig. 7). By manipulating
the interface geometry between the diamond table and the
carbide, the stresses can be managed to optimize the cutter's
performance. (Fig. 8).
The acoustic and SEM analyses are utilized to evaluate
changes in material properties and characteristics throughout
the manufacturing process and to qualify the final product.
DT is utilized to validate the overall development for
abrasion resistance, impact resistance, and thermal mechanical
integrity in order to provide results that closely resemble cutter
failure characteristics observed in the field.
Among DT tests, the G-ratio abrasion test addresses the
diamond abrasion resistance, while heavy wear testing extends
not only into the diamond table but also into the carbide.
Extension tests the ability of the entire cutter to remove rock,
and provides the ability to test all three characteristics of PDC
failure modes: abrasion, impact and thermal degradation.
Cutter Testing Results. Laboratory testing showed the
new PDC cutters to be 20 times more abrasion-resistant than
the industry standard and 3.9 times that of industry premium
cutters, with no loss of impact resistance. (Fig. 9)
Over an 18-month period, 22 different specific cutter
iterations were developed, manufactured, and laboratory
tested. Many of these were also taken to the field for extensive
testing under actual drilling conditions. Field-testing provided
additional knowledge and drove additional insights and
improvements in the new technology cutters.
The result was a highly abrasion-resistant PDC cutter
suitable for applications in which accelerated wear typically
leads to thermal mechanical failure. This includes hard and
abrasive applications where cutting efficiency must be
maintained, and has allowed expansion of PDC applications
into Hard Rock where IADC 4 thru 7 Type Insert RC bits
currently are used.
Field Applications
The innovations incorporated into the new series of bits and
described in this paper provide a number of benefits in terms
of drilling performance. Global force balancing reduces lateral
and axial vibration to maximize ROP, while energy balancing
evenly distributes cutter forces, reducing impact damage and
uneven wear. Use of new PDC cutters with greater TMI offers
significantly increased abrasion-resistance with no loss of
impact-resistance, effectively drilling even hard rock
formations.

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CLAYTON, SHILIN, LEFORT

While specific case histories will be detailed in

forthcoming papers, the following summaries describe typical
performance to date of the new series PDC bits, designated
FM3000 with the new highly abrasion-resistant PDC
cutters, designated Z3:
Travis Peak Formation. The Travis Peak formation in the
Oak Hill field in East Texas comprises primarily very fine
grained sandstone interbedded with shale and mudstone.
Traditionally the interval could be drilled only by several
IADC 647Y to 817Y insert bits. Recent efforts of using PDC
bits to drill this section have been made with only marginal
economic improvement. 10-11
A new PDC bit designed based on the principle described
in this paper, namely, a 7-7/8 FMX753 with the advanced Z3
cutters, successfully drilled 1213 feet of at 29.6 feet/hour,
outperforming the next-best offset by 34% more footage and
7% better ROP.
The FMX753 drilled 58% more footage at a 40% higher
ROP than the average of all competitor offsets in the field,
including one offset that utilized two competitor bits. Even
when combined, those two competitor bits did not equal this
single run performance, which dropped cost per foot from a
high of $73.54 to just $19.20 per foot. (Fig. 10).
In addition, the bit was pulled in repairable condition with
a dull grade of 1-2-WT-S-X-I-CT-PR. By comparison,
competitor designs were not repairable and had an average
dull condition of 6-8-RO-N/S-X-3-BT-PR. (Fig. 11).
Almond Formation. This new technology has also
successfully drilled to TD in the Almond formation, an
extremely tough, interbedded formation at the end of a long
tough run. For this application, an FMX655 was designed with
an aggressive cutting structure incorporating the new Z3
cutters, as well as continuous spiraling along bit cutter blades
through the gage pad for optimized distribution of lateral
forces.
The bit successfully drilled the Almond formation to well
TD at an average ROP of 50 ft/hr, establishing a new ROP
performance record. In addition to achieving the best
penetration rate, the bit also resulted in the best dull condition
of any bit run in the Almond, and was pulled in re-runnable
condition.
Parkland Field Formation. In this case a 7-7/8-in.
FM3645 drilled 1162 meters in 44.5 hours to achieve the
fastest ROP in the Parkland Field to date, 26.11 m/hr. The bit
outperformed all offset bits in this application, achieving a
record average ROP of 26.11 m/hr. As a result of this
outstanding ROP performance, the customer realized
approximate savings of $31,000.
Red Rock Formation. In this case, an 8-3/4-in. FM3541
drilled significantly greater footage than all offsets, while
maintaining a competitive ROP. The FM3541 bit drilled a
total 874 meters, compared to the next-best offset performance
of 240 meters. The bit also maintained an average ROP of
5.67 m/hr to outperform the next-fastest ROP of 3.8 m/hr. As
a result, the operator saved the cost of another bit plus trip
time, for approximate total savings of $28,900.

SPE/IADC 91840

application to hard rock drilling. In direct offset comparisons,

the advanced series of PDC bits fitted with the new cutters
delivered significant increases in footage drilled and rate of
penetration.
The innovations incorporated into the new series of bits
and described in this paper provide a number of benefits in
terms of drilling performance:
Global force balancing provides maximized ROP with
reduced lateral and axial vibration.
Energy balancing evenly distributes cutter forces, reducing
impact damage and uneven wear while promoting improved
ROP.
Transition Drilling Modeling allows for faster transitioning
with reduced impacts and increased toolface stability.
New PDC cutters with greater TMI offer significantly
increased abrasion-resistance with no loss of impactresistance, effectively drilling even hard rock formations.
Designers now have the ability to easily evaluate lateral,
torsional, and axial cutter forces and work. Analysis of the
distribution of these parameters from cutter to cutter, blade to
blade, and between different bit profile segments has aided in
the discovery of features that will continue to improve overall
bit performance.
References
1. T.M. Warren, J.F. Brett and L.A. Sinor, "Development of a Whirl
Resistant Bit", SPE Drilliing Engineering, 5 (1990) 267 274.
2. T.M.Warren and L.A.Sinor, "PDC Bits: Whats Needed to Meet
Tomorrows Challenge", paper SPE 27978, presented1994.
3. G.E.Weaver, R.I.Clayton, "A New PDC Cutting Structure
Improves Bit Stabilization and Extends Application into Harder
Rock Types", paper SPE/IADC 25734, presented 1993.
4. Ortega and D. A. Glowka, "Frictional Heating and Convective
Cooling of Polycrystalline Diamond Drag Tools During Rock
Cutting", SPE Journal of Petroleum Technology, 24 (1984)
pp.121-128.
5. D.A. Glowka, and C.M. Stone, "Effects of Thermal and
Mechanical Loading on PDC Bit Life", SPE Drilling
Engineering, 1 (1986) 201-204.
6. D.A. Glowka, "Use of Single-Cutter Data in the Analysis of PDC
Bit Designs: Part 1 Development of a PDC Cutting Force
Model," SPE Journal of Petroleum Technology, 41 (1989)
pp.797-849.
7. C.J. Langeveld, "PDC Bit Dynamics", paper IADC/SPE 23867,
presented 1992.
8. J.M.Hanson, W.R.Hansen, "Dynamics Modeling of PDC Bits",
paper SPE/IADC 29401, presented 1995.
9. S. Chen, and J. Dahlem: Development and Field Applications of
Roller Cone Bits with Balanced Cutting Structure, paper SPE
71393 presented at the 2001 SPE / ATCE Annual Meeting, New
Orleans, 30 September 2001.
10. E.J.Schell, D. Phillippi, ect, New, Stable PDC Technology
Significantly Reduces Hard Rock Cost Per Foot, paper
SPE/IADC 79797 presented at the SPE/IADC Drilling
Conference held in Amsterdam, The Netherlands, Feb., 2003.
11. R. Fabian, S.Johnson, ect, Enhancements in Design Technology
and Performance of Stable PDC Bits Revolutionize Hard Rock
Drilling in East Texas Fields, Addendum to SPE/IADC Paper
No.79797, IADC/SPE 87098 presented at the IADC/SPE
Drilling Conference held in Dallas, Texas, USA, March,2004.

Conclusions
A series of PDC drill bits incorporating a new highly abrasionresistant PDC cutter has extended effective PDC bit

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SPE/IADC 91840

NEW BIT DESIGN, CUTTER TECHNOLOGY EXTEND PDC APPLICATIONS TO HARD ROCK DRILLING

Acknowledgments
The authors would to thank Halliburton and Security DBS for
permission to present this paper. Collective thanks to all the
operators, contractors and field personnel who collaborated to
make these runs possible. Special thanks go to Larry Eichman,
Robert Gum, Charlie Cogdill, Brian Davies, and Dave Herman
for their efforts on the case histories used in this paper.

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CLAYTON, SHILIN, LEFORT

Face
surface

Fig. 1 Previously used cutter/rock interaction model.

Face
surface

Cylinder
surface

Chamfer
surface

Fig. 2New cutter/rock interaction model divides cutting edge into three surfaces, each with its own force model.

Wear Profile
2.5

Cutter Tip
Exposure Line
Predicted Wear

1.5

Bit Height

0.5

-0.5

-1

-1.5
1

3
Bit Radius

Fig. 3Wear profile predicted with numerical bit model.

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SPE/IADC 91840

SPE/IADC 91840

NEW BIT DESIGN, CUTTER TECHNOLOGY EXTEND PDC APPLICATIONS TO HARD ROCK DRILLING

Axial

Axial

Fig. 4Bending moment generated by uneven distribution of axial forces over cutter

Change Percent Torque Plot

8-1/2" FM3663

Change Percent Torque Plot

8-1/2" FM2663
3.0

3.0

2.5

35

33

31

29

27

25

23

21

19

17

15

13

35

33

31

29

27

25

23

21

19

17

15

13

11

0.0
7

0.0
5

0.5

0.5

1.0

11

1.0

1.5

1.5

After
2.0

2.0

Change in Percent Torque

Before

Change in Percent Torque

2.5

Cutter #

Cutter #

Fig. 5 Cutter locations are manipulated to reduce maximum change in torque for individual cutter and to distribute change in torgue equally
over more cutters.

Fig. 6Thermal Mechanical Integrity is the third dimension of PDC cutter per formance.

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CLAYTON, SHILIN, LEFORT

Fig. 7Interface geometry between diamond layer and carbide is optimized to reduce residual stress.

Fig. 8Interface geometry of new Z3 PDC cutter.

1.6E-02
New Z3 PDC cutter

1.4E-02

Premium Cutter

Cutter Wear (in3)

1.2E-02
1.0E-02
8.0E-03
Industry Standard

6.0E-03
4.0E-03
2.0E-03
IADC "1" Wear (1/8 Diameter Worn)

0.0E+00
0

2000

4000

6000

8000

10000

Volume of Rock Removed (in3)

12000

14000

Fig. 9New cutter offers 20 times the abrasion resistance of industry standard cutters.

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SPE/IADC 91840

SPE/IADC 91840

NEW BIT DESIGN, CUTTER TECHNOLOGY EXTEND PDC APPLICATIONS TO HARD ROCK DRILLING

Offset PDC bits

New
PDC

Fig. 10Travis Peak interval drilled by new PDC bit and recent comparable offset PDC bit performance.

Fig. 11Dull condition after drilling 1213 ft of Travis Peak formation at almost 30 ft/hr, outperforming offset by 58% more footage and 40%
higher ROP.

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