Drag Bit Wear Model
A. Sinor, SPE, and T.M. Warren, SPE, Amoco Production Co.
Summary. A performance model for polycrystalline-diamond-compact (PDC) bits was modified to include the wear prediction of in-
dividual cutters. Wear predictions are based on the geometry of each cutter, the rock type, the forces acting on the cutter, cutter velocity ,
and cutter temperature. The results of predicted and actual cutter wear for different 8Y2-in. [21.6-cm] field-worn PDC bit designs are
shown. The worn geometry of each cutter was measured and compared with the model's prediction.
Laboratory performance tests were also conducted with similar bit designs to quantify the effect of bit imbalance. Reduced rate of
penetration (ROP), drilling an overgauge hole, and increased cutter wear and breakage can result from bit imbalance.
Introduction
The successful use of PDC bits depends on obtaining a sufficient
ROP and length of run to make their application economical. Both
the ROP and length of run (bit life) depend on the bit design, oper-
ating parameters, and formation properties. Changes in operating
parameters, which result in an increase in the ROP, such as in-
creasing weight on bit (WOB) or rotary speed, will also increase
bit wear rate.
Field drilling experience has shown that in some formations no
PDC bit design has been economical, while in other formations spe-
cific bits have been identified as having a high probability of success.
The performance of identical bits run in offset wells is often quite
different.
This paper describes experimental testing and analytical modeling
being used to gain a better understanding of the interaction of the
variables that determine the success or failure of a particular bit
run. A poftion of the work dealing with modeling cutter forces and
instantaneous bit performance was presented by Warren and
Sinor.' The current paper presents an expansion of this work to
include the modeling of the abrasive wear of a PDC bit and labo-
ratory observations of the effects of dynamic forces on the bit.
Type. of Wear
PDC bit cutter wear can be divided into two categories, depending
on the basic cause of the wear. The first category, abrasive wear,
is steady-state wear that is normally associated with the development
of uniform wear-flats and the gradual degradation in ROP over the
bit life. It is a function of the force applied to the cutter, cutter tem-
perature, cutter velocity, formation properties, and cutter properties.
Abrasive wear was modeled and relatively accurate predictions were
made of the detailed cutter wear experienced on bits run in the field.
The second category of wear is the result of dynamic loading
of the cutters. This form of wear is typified by chipped, broken,
and lost cutters. Dynamic loading can be caused by abrupt changes
in the surface drillstring control or by forces induced by cutter/rock
interaction. The current work concentrates on evaluating the cutter
placement to determine the inherent stability of a particular bit
design. The stability is determined by evaluating the radial and cir-
cumferential forces that tend to cause the bit to rotate about an axis
other than the center of the hole.
Force balancing of PDC bits is generally recognized to be im-
portant for optimum performance and bit life, but its application
to commercial designs historically has been made by placing the
cutters where they appeared to be "balanced" on the basis oftheit
geometrical location only. If the radial forces acting on the bit are
not balanced, the bit tends to rotate off-center, resulting in reduced
ROP and accelerated wear. Drilling with an imbalanced bit can
sometimes result in an overgauge hole, depending on the amount
of gauge stabilization and the amount of applied WOB. The model
presented in this paper calculates an imbalance force and direction
but does not predict the effect on performance or wear.
Model Background
In the early 1970's, Larsen-Basse 2 surveyed the literature on wear
of hard metals and concluded that abrasion and thermal fatigue were
the primary causes of wear-flat development. Laboratory wear
studies in Jack Fork sandstone showed that PDC cutter wear de-
pended on cutter speed and wear-flat temperature. 3 The wear study
Copyright 1989 Society of Petroleum Engineers
128
suggested that increases in temperature result in exponential in-
creases in wear rate.
Glowka and Stone 4 discussed the wear mechanisms for PDC bits
and the dependence of wear on cutter temperature. Above 1,382 OF
[750°C], wear was shown to accelerate because of thermal deteri-
oration and diamond grain pUllout, resulting in catastrophic cutter
failure. At temperatures below 1,382°F [750°C], the primary mode
of wear was described as microchipping abrasive wear. A log-log
plot of experimental wear rates vs. wear-flat temperature showed
that the wear rate increased dramatically above 662°F [350°C].
Because of the accelerated wear rate above 662°F [350°C], it is
defined as the critical cutter temperature. Glowka and Ortega's5,6
temperature model, along with an empirical wear function based
on laboratory and field data, was used in the model discussed in
this paper.
Glowka derived the following expression for wear-flat tem-
perature:
kfFnvf[ 3V7r ( l00v
Tw=Tf + - - 1+ - f khf - -
)'h]-l
Aw 4 Lwexf
The thermal response function, f, is the effective thermal resistance
of the cutter and is a function of cutter configuration, thermal prop-
erties, and cooling rates. The temperature, and thus wear rate, of
a PDC cutter is also affected by cutter balling. It is generally agreed
that certain mud types reduce the tendency for bit balling. The model
does not predict cutter balling, but the effect of balling on cutter
cooling can be simulated by changing the convective heat-transfer
coefficient, h. Glowka and Stone 4 showed the reduction of cutter
cooling as a function of cooling rate and rock-flour thickness to
be a factor of 10 for shale 0.039 in. [0.1 cm] thick on the cutter face.
The actual wear rate of a cutter is a function of its contact stress
and temperature. The model presented in this section relies heavily
on Glowka and Stone's work to provide an estimate of cutter tem-
perature, which is then related to wear rate. Nonlinear regression
analysis was used to develop an equation for the tabular data
presented by Glowka and Stone 4 for f as a function of cooling and
cutter wear-flat area (WFA). A constant cooling rate of 1,800
Btu/(hr-ft2_0F) [1.0 (W/cm2. 0C)] was assumed for the calcu-
lation. Using this information, along with values available from
the PDC force model presented in Ref. 1, the cutter temperature
can be calculated from the equation above.
Once the cutter temperature is known, the wear rate is estimated
from an empirical relationship between wear rate in Jack Fork 3
sandstone and cutter temperature. A relative formation abrasiveness
is used to relate the wear rate in Jack Fork sandstone to the par-
ticular rock being drilled by the model.
Each cutter is divided into a number of discrete elements in the
model. The height worn off each element for a particular timestep
is calculated from the previously determined wear rate. Wear-flat
length is based on the height worn off the element and cutter ge-
ometry. The axial force applied to the cutter is divided into a non-
productive component supported on the WFA and a component that
causes chip generation. Fig. 1 is a flow chart of the PDC per-
formance model and Fig. 2 is a schematic of a cutter with wear-
flat development in progress.
In addition to incorporating bit wear into the model, the cutter
force model was modified to provide a more general prediction.
A "bit factor" was used in the previous work to account for a
SPE Drilling Engineering, June 1989
 Fig. 1-Flowchart of poe performance and wear model.
modeling deficiency with certain bits. The deficiency was corrected
with an improved analytical model for cutter backrake. The per-
formance model uses cutter geometry, rock properties, and the ap-
plied operating conditions to calculate individual cutter forces, cutter
temperature, and WFA in contact with the rock. Integration ofthe
forces across the bit face gives the torque and WOB for a particular
ROP.
Example Model Results
Three basic bit styles, shown in Fig. 3, were used in the test
program. Bit A is 8:)4 in . [22.23 cm] in diameter; Bits Band C
are 8'12 in. [21.6 cm] in diameter. Bit A is a flat-faced, steel-bodied
bit (lADC Type S984) with 36 steel-studded cutters and 4 jets. The
cutters are aligned in three spirals originating from the bit center.
The bit is a field run "dull" with a WFAofO.64 in. 2 [4.13 cm 2] .
Bit B, with a slightly rounded face, is a steel-bodied bit (lADC Type
S175) with 39 cutters and 5 jets. A new bit and a filed worn bit
of this design were used in the laboratory testing . Bit C is a steel-
bodied, tapered-profile bit (lADC Type S354). The cutting structure
BIT A BIT B
Fig. 3-81ts used In tests.
SPE Drilling Engineering, June 1989
Fig. 2-Schematic of single cutter with wear-flat development.
consists of 4 blades with 37 cutters. This bit was tested in the labo-
ratory, run in the field , and then retested in the laboratory .
Performance calculations for Bit A in Carthage limestone at an
ROP of 30 ft/hr [9 . 1 m/h] are presented in Table 1 and Fig. 4 .
The bit was computer-worn from a new condition to a total WFA
of 0.64 in. 2 [4.13 cm 2] to simulate the actual measured cutter
WFA (see Ref. 1).
The computed tabular data show the cross-sectional cut area, rock
volume removed per revolution, the angle of contact between the
cutter and the formation, cutter forces, cutter speed , wear-flat tem-
perature, WFA, effective siderake, and effective backrake. The in-
dividual cutter calculations are vectorially summed across the bit
face to give the imbalance force and direction referenced to a par-
ticular cutter, WOB, torque, and total WFA. Cutters 33, 34 , 35,
and 36 are gauge trimmers and do not remove any rock in this
example.
The bit imbalance force is defined as the force tending to push
the bit into the hole wall and is a function of bit design and applied
WOB. An imbalanced bit design generally drills an overgauge hole
BIT C
129
 TABLE 1-EXAMPLE MODEL OUTPUT FOR SIT A

Cutter Cutter Force

Area Volume Angle F x F y F n Velocity Temperature Wear- Effective Effective
2 3
Cutter (in. ) (in. ) (degrees) (Ibf) (Ibf) (Ibf) (m/s) (0C) Flat Siderake Backrake
27 0.0057 0.1081 13.4 335 442 455 0.96 297 0.02150 -1.2 - 25.8
28 0.0054 0.1155 21.3 332 431 463 1.07 306 0.02309 - 3.8 - 25.7
36 0.0000 0.0000 0.0 0 0 0 0.00 65 0.00000 0.0 0.0
29 0.0063 0.1479 26.8 353458513 1.18 330 0.02749 -6.6 -24.2
30 0.0091 0.2301 36.2 419531 657 1.27 366 0.03725 -3.3 -20.5
31 0.0042 0.1125 30.0 231 328379 1.36 315 0.02301 -8.9 -22.4
10 0.0165 0.0988 -9.1 757893905 0.30 296 0.01811 1.8 -23.2
32 0.0011 0.0310 52.6 77 80132 1.36 171 0.01358 -2.6 -24.6
9 0.0137 0.1503 0.6 723 867 867 0.56 329 0.02581 0.2 - 25.1
33 0.0000 0.0000 0.0 0 0 0 0.00 65 0.00000 0.0 0.0
8 0.0110 0.1611 - 3.7 591 735 736 0.75 335 0.02738 - 3.2 - 25.3
7 0.0078 0.1362 1.9 445 578 579 0.89 .316 0.02538 - 2.0 - 25.9
12 0.00860.0218 -17.1 411458480 0.13 198 0.00800 -7.4 -23.2
6 0.0053 0.1059 15.9 344.452470 1.02 290 0.02340 -5.9 -26.6
34 0.0000 0.0000 0.0 0 0 0 0.00 65 0.00000 0.0 0.0
5 0.0071 0.1587 18.4 419 547 576 1.13 331 0.02981 -1.8 - 25.6
4 0.0051 0.1237 32.2 290 361 427 1.22 305. 0.02385 - 3.1 - 23.5
13 0.0115 0.0895 0.5 631 714714 0.39 308 0.01655 -9.2 -25.9
3 0.0046 0.1243 35.6 263 352 433 1.36 315 0.02714 - 8.2 - 23.7
2 0.00030.0076 7.6 18 40 40 1.34 117 0.00826 -18.0 -17.2
14 0.0077 0.0941 3.1 422542543 0.62 277 0.01951 -0.8 -24.8
1 0.0008 0.0204 18.8 49 99 104 1.35 152 0.01509 -17.5 -18.1
15 0.0070 0.1099 6.0 381 508510 0.80 295 0.02110 -0.9 -24.5
16 0.0065 0.1207 8.7 376512517 0.93 292 0.02399, -6.6 -25.2
17 0.0067 0.1370 19.0 399519549 1.05 321 0.02634 -6.2 -25.6
18 0.0030 0.0674 24.6 194276303 1.15 244 0.01911 -0.1 -25.3
19 0.0024 0.0602 33.5 161 207248 1.26 280 0.01448 -0.6 -26.0
23 0.0151 0.0605 -10.5 678800814 0.21 250 0.01447 -2.1 -22.9
35 0.0000 0.0000 0.0 0 0 0 0.00 65 0.00000 0.0 0.0
20 0.0015 0.0395 13.7 78 140 144 1.34 209 0.01249 -16.4 -18.4
21 0.0009 0.0230 37.3 77 98123 1.36 195 0.01148 -3.2 -29.7
22 0.0004 0.0099 32.2 29 47 56 1.36 130 0.00970 - 7.8 - 24.2
24 0.0124 0.1144 0.7 614744 744 0.47 304 0.02027 1.0 -24.2
25 0.0095 0.1264 2.8 514642643 0.67 307 0.02291 -0.4 -25.0
26 0.0066 0.1092 5.8 354480483 0.84 293 0.02072 0.9 -23.9
11 0.01660.0159 -12.6 496692709 0.05 130 0.01129 6.5 -14.2

Rotary speed, rev/min 120

ROP, ftIhr 30
Rotating time, hours 5
Imbalance force, Ibf 1,056
Percent imbalanced 7
Imbalance force angle, degrees 71
Radial imbalance force, Ibf 249
Circular imbalance force, Ibf 1,156
WOB,lbf 14,576
Bit torque, ft-Ibf 2,247
Total WFA, in.2 0.643

and causes dynamic cutter loading and reduced ROP. Cutter balance
and its effect on wear are discussed later.
Laboratory Testing
A computer-controlled laboratory drilling rig 7 was used to collect
the drilling data for the bits shown in Fig. 3. The bits were tested
in new and dull conditions with Carthage limestone {unconfined
compressive strength (UCS) = 16,000 psi [110 320 kPa]}, Berea
sandstone (UCS=7,OOO psi [48 265 kPa]), and Catoosa shale
(UCS=6,500 psi [44 818 kPa]). The flow rate, rotary speed,
borehole pressure, and applied WOB were controlled during each
test.
The laboratory-measured ROP with Bit B in the new and field-
worn condition (WFA=2.8 in. 2 [18.1 cm 2]) is shown in Fig. 5.
The solid curves represent the model predictions for the new bit
and for the case where the bit was dulled by the model to a WFA
of2.8 in. 2 [18.1 cm 2]. A closeup of the individual cutters is shown
in Fig. 6. The cutters near the gauge show large, flat wear surfaces
that extend the length of the carbide stud but show little evidence
of cutter damage. The bit record showed that it averaged 6 ft/hr
[1.8 m/h] at 14,958 ft [4559 m] for 170 hours with an oil mud in
a relatively firm formation. Wear and performance predictions were
made by wearing the new bit profJ.J.e until the simulated WFA
matched the measured WFA. This required 180 hours of drilling
time at 15,000 lbf [66 723 N] WOB and a rock abrasiveness of
20% of Jack Fork sandstone.
Fig. 7 shows the measured profJ.J.es for the new, field-dull
(WFA=2.8 in. 2 [18.1 cm 2 ]), and simulated worn profJ.J.es. A
reasonably good match was made even though the wear predictions
were made from an identical design, which inevitably has slightly
different cutter placement because of manufacturing tolerances. In-
dividual cutter temperatures and forces for the first 10 cutters shown
in Fig. 7 are plotted in Fig. 8 at an ROP of 30 ft/hr [9.1 m/h] in
Carthage limestone. The worn cutters experience higher loading
because of the WFA, but the temperatures are generally lower than
those of the new case. Cutter 2 experiences the highest loading in
each case, but the cutter temperature is generally lower than that
of the cutters radially outward from the bit center because of their
higher velocity.
The practice of "breaking in a bit" is important with POC bits.
Some cutters on a new bit may experience higher-than-anticipated
initial loading because of the manufacturing tolerance on cutter
placement. A combination of high loading and small contact area
can result in accelerated wear or premature failure from cutter

130 SPE Drilling Engineering, June 1989

 Fig. 6-Close-up of dull cutters on Bit B.

o
o
r--:

o
o
<ci

Fig. 4-Angular position of cutters, Bit A. o

o New
Ll'i

o
·0
150 Field Dull
.£ "'"
140 ~ WFA=2 .B in.2
130 • New OJ
'OJ 0
...
.I::.
120 -
• Field Worn
Model 120 REV/MIN
:co
M
;: 110 450 GAUMIN
a) 100 1250 BOTTOMHOLE PRESSURE
<0 90 CARTHAGE o Simulated Wear
o
a: N WFA=2.B in.2
c 80
0 70
~ 60
Q)
c 50
Q)
Q. 40
30 o
o
20 o+-____~----~----~------._--~
10 0.00 lOO 2.00 3.00 4.00 5.00
Radius, in.
00 5 10 15
Weight On Bit, 1,000 Ibl Fig. 7-Bit B cutter profile (new, worn, and simulated worn).

Fig. 5- Blt B model simulation for new and worn condition.

1500 r-----~1~20~R~E!!:'V~/M~I:':':N--------
chipping and wear-flat temperature. Any cutters that have greater • New 450 GAUMIN
eDull 1250 BOnOMHOLE PRESSURE
exposure than their planned design may be worn to the desired ;Q ROP-30
0
profile by careful break-in. Running too aggressively during the ai 168 C CARTHAGE 200 0 C
break-in period can damage the overexposed cutters . As drilling
~
~ 1000 ,
A,
,
201" C ,.~
p ~,,'
,.211 C
\
0

proceeds, nonnal wear will increase the area of cutter contact, which
1190 C ~44° C ~79° C I 1900 C \
will allow use of higher weights without sacrificing bit life. Fig . G> II ~~ 182 C I 0
\
9 shows the predicted temperature distribution for the first 10 cutters
on the new Bit B at different ROP's. Note that several cutters are
:3
(ij
..,, I
I -.1790 C

close to or over the critical temperature of 662°F [3S0°C] at 70 (,) 500 16Y· C
and 90 ft/hr [21.3 and 27:4 m/h) . Cutters 1 through 10 represent
a radial distance of about 2.5 in. [6:4 cm], and the cutters radially
~
outward experience even higher temperatures.
The laboratory test results and model performance predictions
of Bit A in Carthage limestone, Berea sandstone, and Catoosa shale
are plotted in Fig. 10. The measured cutter profile is shown in Fig.
11. The performance was based on a simulated WFA of 0.64 in. 2
[4.13 cm 2 ) , which was previously measured. The model predic-
Fig. 8-Blt B temperature modeling for first 10 cutters (new
tions for the Carthage limestone and Berea sandstone were accurate, and dull).
but the model predicted higher ROP in the shale than was measured.

SPE Drilling Engineering, June 1989 131

 450
150
() 9Oft/h, 140 120 REV/MIN
0 450 GAUMIN
350 130 • Carthage 1250 BOTTOMHOLE PRESSURE
~ 120 o Berea CARTHAGE
~
300 1: WFA~O . 64
~
Q)
~ 110 • Shale
D- ai 100 -Model
E (5 90
~ a:
80
1ii c
u::.!. 10ft/h, 0 70
<11
150 ~ 60
Qi
~ 1250 BOTTOM HOLE PRESSURE c
Q)
50
40
450 GAUMIN 0..
120 REV/MIN 30
20
00 11 10
0
0 5 10 15 20
Weight On Bit, 1,000 Ibf
Fig. 9-Blt B temperature modeling for new bit at different
ROP's. Fig. 10-Blt A performance modeling with WFA = 0.64 In.2

The lower laboratory performance in shale is assumed to be re-
lated to cutter balling, which is not covered by the model. The data
for Bits A and B demonstrate that the model performance based
on wear is valid, provided that the cutters are being cleaned.
Field Study
To provide a more rigorous test of the performance and wear model,
Bit C was tested on the laboratory drilling machine and then tested
at a research field drilling facility located just outside Tulsa, OK.
The drilling facility uses a computer and servocontrol system to
control the WOB and rotary speed during normal drilling opera-
tions. It is capable of drilling to 3,000 ft [914.4 m]. A special feature
of the computer control system is the ability to tag bottom after
each connection with less than 2,000-lbf [8896-N] WOB, pick up
a few inches, take tare readings, and then begin drilling. The only
manual interventions required are to make connections and to in-
itiate performance tests at predefined depths.
Two offset wells were previously drilled and logged at the field
facility. The first well was continuously cored from surface to total
depth (TD) with 47's-in. [1l.l-cm] core bits. The second well was
drilled with 8'h-in. [21.6-cm] roller-cone bits and later logged with
conventional tools to obtain resistivity, sonic, gamma ray, and shear
sonic. The data from these two wells were used to help establish
the testing sequence for Bit C and to provide knowledge about the
formations being encountered during drilling.
The objective of the field test was to pull the bit before and after
certain lithology sections to evaluate the amount of wear and wear
rate. After the field test was completed, Bit C was measured and
retested with the laboratory drilling rig.
Fig. 12 is a typical plot of pertinent drilling parameters from 805
to 835 ft [245.4 to 254.5 m]. The WOB and rotary speed are
generally constant, while the ROP and torque vary with lithology
change. From this figure, it appears that the bit drilled the section
at an average ROP of 50 to 60 ftlhr [15.2 to 18.3 m/h]. Fig. 13
shows the same data plotted vs. time instead of depth. A quick glance
shows that the bit quit drilling (ROP dropped below 1 ftlhr [0.31
mlh]) through several intervals. The bit actually averaged about
18 ft/hr [5.5 m/h], which is not evident from Fig. 12. If this per-
formance had been obtained on a production well, the bit might
have been pulled for "not drilling."
The "hard streaks" were not evident from offset roller-cone-bit
data, which showed a minimum ROP of65 ftlhr [19.8 mlh] through
this interval, but are very pronounced with the drag bit. It appears
that the crushing mechanism of the roller-cone bit is more effective
in the harder rock than the shearing mechanism of the drag bit.
The fine, detailed changes in lithology, which were obtained by

o
o
.....:
All Cutters 810
o
o
cO
815
o Spiral 1 .1:_ 820 .........._ _
.~
.S;

E
Cl
'iii
0
Ln

Spiral 2
-o
..c
c..
Q) 825
::C~ ..,.
830
o Spiral 3
o 835
M

o 20
o
c-..i +0.-00----rt-00--2..-00--3..-.00--4T".0-0---'5.00
Radius, in Fig. 12-Depth·based field data for Bit C.

Fig. 11-Blt A cutter profile.

132 SPE Drilling Engineering, June 1989

 WFA=1.4 in~

(§) Measured
en
....
C>
C>
c.O 20 (§) Profile
::J
o
.r:
~ 17.5 a
a
21 (§)
Q) .n Predicted 22 tf:\
E Profile ~
i= 23
18
24c§)
20
25c§)
Fig. 13-Tlme-based field data for Bit C.
26((5)
27(gJ

a 28~
~~0.~00~-1~.0~0--~2.~00~--3'.0-0---4~.~00----'5.00
Radius, in.

Fig. 15-Wear modeling for Blade 3 on Bit C (WFA= 1.4In. 2 ).

o
o
..,.;

.~
o WFA=2.4 in.2
.~ -.:::t
C>
irn C>
r--:
00) 0
J:~
CO")

C>
Measured
o
C> Profile
o c.O
N

C>
0 C>
~ .n
Predicted
0
0
c:i
0 C>
.£ a-.i
Profile

0.00 1.00 2.00 3.00 4.00 5.00

~
Radius, in. .c.
Cl
·05
J: aa

25~
Fig. 14-Blt C cutter profiles (new WFA = 1.4 In.2 and worn
WFA=2.4In.2). M·

26~
a
the computer-controlled drilling rig and data-collection system, were N
not discernible from the gamma ray and resistivity tools because
bed resolution from the drilling data is much better than that from 27
the logging data.
The measured cutter profiles for the new bit and after the second
and third trips out of the hole are plotted in Fig. 14. "V" -shaped
wear was noted on several cutters during the first trip. A model
wear simulation performed before the trip predicted the V-shaped
a
C>
o~-----.------.------.----~rL-----,
28~
wear. The simulated wear is believed to be the first documented 0.00 1.00 2.00 3.00 4.00 5.00
case in which both cutter wear rate and actual shape were simu- Radius, in.
lated. The resolution of the wear prediction would not have been
possible without the small cutter elements used by the force and Fig. 16-Wear modeling for Blade 3 on Bit C (WFA = 2.4 In. 2).
wear models. Figs. 15 and 16 are overlays of the predicted vs. actual

SPE Drilling Engineering, June 1989 133

 High Density Wear

Fig. 17-Close-up of cutter wear on Bit C. .
wear for Blade 3 at WFA's of 1.4 and 2.4 in. 2 [9.0 and 15.5 cm2] ,
respectively. A close-up of the V-shaped wear at a total WF A area
of 2.4 in. 2 [15.5 cm2] is shown in Fig. 17. The difference in cutter
wearflat shape between Bits B and C (flat vs . V-shaped) is related
to the cutter density (Fig. 18). High cutter density generally re-
sults in flat wear, while low density results in V-shaped wear.
The field computer was used to obtain performance tests (WOB
steps) that are similar to the tests performed with the laboratory
drilling rig. Fig. 19 shows the field data and model performance
comparison at 90 rev/min, 950-ft [289.6-m] depth, and 0.8 relative
rock-strength factor. The computed rock strength was derived from
the calculated formation compressive strength obtained from Ref.
8. A fairly good match is evidenced by the plot. The WFA was
assumed to be about 2.2 in. 2 [14.2 cm 2], judging from a final
WFA of 2.4 in. 2 at 1,060 ft [15.5 cm 2 at 323.1 m], which is where
the bit was pulled (third trip). A 5% error in WFA was simulated
and had little effect on the model comparison.
The computed temperature distribution for the nine cutters on
Blade 3 plotted in Figs. 15 and 16 is shown in Fig. 20. Note that
the temperature distribution for the first four cutters (radially from
bit center to 2.5 in. [6.4 em)) in Carthage is higher than the tem-
peratures for the cutters in Fig. 9. The cutters in Figs. 9 and 20
have roughly the same velocity, but the cutters in Fig. 20 have in-
creased loading as a result of cutter density.
Dynamic Bit Loading
The previous model discussions and laboratory testing dealt
primarily with steady-state drilling and abrasive cutter wear.
Unsteady-state wear is equally important but has yet to be included
in the model. The performance model predicts the magnitude and
cc.~
Low Density
o
CID)
Fig. 18-Schematlc of V-shaped vs. flat wear.
o
direction of bit imbalance, which, in many cases, is a significant
contributing factor to unsteady wear. The relation of bit imbalance
to bit performance and cutter wear, however, can be shown in lab-
oratory testing but is not easily calculated.
A laboratory study of a PDC bit design by Daniels and
Thompson 9 showed the effect of improper cutter placement on bit
performance. A bit was improperly manufactured, resulting in some
of the cutters not contacting the formation when drilling. Excessive
torque and poor ROP were observed because of bit chatter. in-
spection of the bottomhole pattern showed a lobed proftle with dis-
crete steps being generated by excessive engagement of individual
cutters. A second bit was fabricated, and close attention was paid
to cutter "trueness." The second bit showed a dramatic im-
provement in performance with no chatter or torque problems.
In the process of developing a commercial PDC bit design, three
similarly bladed bits (IADC Type M312) were manufactured with
similar designs but slightly different cutter placements. Detailed
cutter measurements and performance calculations were made before
testing with the laboratory drilling rig'. Bits 1 through 3 had calcu-
lated imbalance forces of 29, 14, and 7%, respectively. The re-
sults of these tests ip Carthage limestone are shown in Fig. 21. At
12,500-lbf [55 603-N] WOB, Bit 2 drilled 55% faster than Bit 1
and Bit 3 drilled 135 % faster than Bit 1. A lobed bottomhole proftle
was noted, along with the hole being 0.3 in. [0.8 cm] out of gauge
for Bit 1. The bottomhole pattern of Bit 1 showed that the bit was
chattering because of cutter placement, which resulted in reduced
ROP and would ultimately result in reduced bit life,
An 8~-in. [21.6-cm), IADC M914, three-bladed drag bit de-
signed to drill soft, "gumbo-type" formations was tested in Catoosa
shale and Carthage limestone. The particular bit tested has a suc-

150 450r-----------------------------,
ROP=30
90 REV/MIN
140 350 GAUMIN
BLADE 3
()
130 DEPTH 947 o
• Field Data m 350~----------------~~~=---------_+----------------~
.c 120 -Model ROCK STRENGTH .. 0,8
:s
:= 110 WFA .. 2,2
f! 300
Qi 100 Q)
iii 90 a.
a: E
c 80 ~
0 70 iii
~ 60 u:: 150
Q)
cQl 50 ~
0.. 40 ~
30
20
10
0 00 1 2 3 4 5 6 7 8 9 10
0 4 6 10 Cutlers (Ordered From Center to Edge)
Weight On Bit, 1,000 Ibf
Fig. 20-Temperature modeling for Bit C at different wear-
Fig. 19-Performance modeling of field data for Bit C. flat areas.

134 SPE Drilling Engineering, June 1989

 100 45
120 REV/MIN
90 • Bit 1 450 GAUMIN 40 • Test 1
OBit 2 1250 BOTTOM HOLE PRESSURE • Test 2
1: 80 • Bit 3 CARTHAGE 1: 35
=
S
III
70
60
=
ai
a;
30
a:: a:: 25
c 50 c
0 0
20
~ 40 ~
Q) Q)
c c 15
Q) 30 Q)
CL CL
20 10
5

5 10 15 20 0 5 10 15
Weight On Bit, 1,000 Ibf Weight On Bit, 1,000 Ibf

Fig. 21-Effect of Imbalance on laboratory performance. Fig. 22-Laboratory performance for three-bladed bit.

cessful track record in the U.S. gulf coast area. It drilled the Catoosa
shale at 89 ftlhr [27.1 mlh] at 9 ,700-lbf [43 148-N] WOB and 120
rev/min with very little torsional vibration and no bit balling. The
conclusion from these tests was that it was well suited for drilling
soft shale rock.
The first test in the limestone was terminated at 1O,200-lbf
[45 372-N] WOB because of excessive torsional vibrations. The
ROP for this test is shown in Fig. 22. At the conclusion of this
test, the cutters on the bit near the "breakover" were significantly
chipped. A second attempt to run the bit in Carthage was also ter-
minated because of high torsional vibrations.
Comparison of the data in Fig. 22 for Runs I and 2 indicates
that the cutters chipped after the 4 ,000-lbf [17 793-N] WOB point
and that no additional chipping occurred after Run 1 ended. This
is concluded from the change in the slope of the ROP curve at 4,000
lbf [17793 N] and from the fact that Run 2 drilled significantly
more slowly than Run I at the low weights but extrapolates to the
same ROP as the end of Run I .
The bottomhole pattern in the Carthage showed seven distinct
spiral lobes (Fig. 23) . The hole was lis in. [0.3 cm] over gauge.
A third test was conducted in the Carthage to see whether the
bit would drill smoothly at a constant lower WOB of 3,700 lbf
[16 458 N]. Fig. 24 is a plot of the torsional vibrations vs. depth
for this constant-WOB and constant-rotary-speed case. After about
5 in. [12.7 cm] was drilled, the torsional vibrations began to in-
crease and continued to increase until they were greater than the
mean torque; the test was terminated after 18 in. [45.7 cm] was
drilled. Again, the bottomhole pattern showed the seven-lobe spiral
pattern.
An analysis of the calculated bit imbalance force shows that the
bit has an imbalance of about 10% of the WOB force, but almost
all of it results from the circumferential component of imbalance.
This is not much greater than some bits that drilled smoothly. The
placement of all the cutters on three blades with three associated
stabilizer pads seems to have made the bit more susceptible to de-
veloping a lobed bottomhole pattern.
The shale was too weak to allow the lobed pattern to develop,
but the Carthage was competent enough to withstand significant
impact loading. Once the lobed bottomhole pattern begins to de-
velop, it causes torque and WOB fluctuations, which tend to cause
the bit to bounce off bottom. The torque vibration data indicate that
the bit was completely disengaged from the rock at times.
The results of these tests agree in a general way with field obser-
vations that the three-bladed bits are very easily damaged in hard
sections. Hard streaks only a few feet thick are often sufficient to
terminate a bit run.
The torque and torque vibrations for the three-bladed bit are com-
pared to a six-bladed bit in Fig. 25. The six-bladed bit had not only
three full blades with approximately the same number of cutters
as the three-bladed bit, but also three partial blades with an addi-
tional 15 cutters. The torque vibrations for the six-bladed bit are
approximately 15% of the mean torque over the WOB range that
was tested. The vibrations for the three-bladed bit are approximately
equal to the mean torque up to a WOB of 4,000 lbf [17 793 N]
and then remain nearly constant at 1,200 ft-Ibf [1627 N· m].
Fig. 26 shows the ROP obtained from the two tests shown in
Fig. 25. At the low weights, the three-bladed bit drilled slightly
faster, but at the higher weights it drilled considerably more slowly

2.0~----- __-----....",.----. 1400

• WOB Vibration
• Torque Vibration
1200
:a :a
;; 1.5
1000 ~
~ r:
0
r: 800 .~
B10 .0
01 •
15
:>
600 CD
:> ~
!:
::3 120 REV/MIN 400 0
1- .
:i: .05 450 GAUMIN
1250 eoTIOMHOlE PRESSURE
CARTHAGE 200
WOB = 3,700 Ibl
0
00 0.5 1.0 1.5 2.0
Depth, It
Fig. 23- Bottomhole profile In Carthage for three-bladed bit.
Fig. 24-Laboratory vibrational data for three-bladed bit.

SPE Drilling Engineering. June 1989 135

 3~~--------------------------~ 80
• 6 Blade Mean Value
o 6 Blade Vibration 70 . 6 Blades
03 Blades
• 3 Blade Mean Value
:c 2000 03 Blade Vibration ~
01=
60
;;; ai
iii 50
Q) 0:
::::J
e-o o c: 40
0
o ~
to- 1000 "-
Qi 30
c:
Q)
a.. 20
10
10
2 4 6 8 10
Weight On Bit, 1,000 Ibf
Fig. 25- Torque and torque vibrations for three- and six-
bladed bits. Fig. 26-ROP for three- and six-bladed bits.

than the six-bladed bit. The low rate of increase in ROP as WOB
is increased is typical of the laboratory-tested bits that had vibration
problems. It is also interesting to note that the six-bladed bit drilled
about two times faster than the three-bladed bit at 10,000 lbf [44 482
N] but required less mean torque.
The exact cause of the difference in the performance of the three
and six-bladed bits has not been determined. The cutting structures
of both bits are balanced within the normal range. The three-bladed
bit has significantly more effective backrake on the outer cutters
than the six-bladed bit. The three-bladed bit has only three stabilizer
pads compared to six for the other bit. The cause of the excessive
vibrations in the hard rock is probably related to these two factors.
Review
A performance and wear model for PDC bits was developed and
confirmed by laboratory and field data. The model is useful for
evaluating the'mechanical design of a bit for proper cutter placement
and cutter wear. The model is based on static cutter force and wear
calculations. Relatively accurate predictions of cutter wear have
been made of field-worn bits.
Running excessive WOB is detrimental to bit life because of in-
creased cutter temperature and loading. Cutter wear increases ex-
ponentially with increases in cutter temperature. A new cutter
experiences high initial temperatures because of the small initial
contact area, but normal drilling increases the area, allowing higher
bit weights to be run.
Improper placement of cutters can result in dynamic loading,
which is typified by chipped, broken, or lost cutters. The model
calculates the relative stability of a particular design, but the effect
on performance and bit life is not currently modeled. Laboratory
testing, however, verifies the existence of imbalanced bit designs
previously calculated by the model. In some cases, laboratory data
indicate that a particular bit design may have a greater tendency
to drill with high vibration than the force balance calculations in-
dicate.
Tf = fluid temperature, OF [0C]
Tw = mean cutter wear-flat temperature, OF [0C]
v = cutting speed, ft/sec [m/s]
Oif = rock thermal diffusivity, in.2/sec [cm2/s]
Acknowledgments
We thank Christensen, Smith Diamond Services Co., Hughes
Diamond Products, Diamant Boart U.S.A. Inc., and Strata Bit Corp.
for providing bits used in the testing program. Also, special thanks
to Jim Powers, who meticulously measured the new and dull PDC
bit profiles presented in this paper.
References
1. Warren, T.M. and Sinor, A.: "Drag Bit Performance Modeling,"
SPEDE (June 1989) 119-27.
2. Larsen-Basse, G.: "Wear of Hard Metals in Rock Drilling: A Survey
of the Literature," Powder Metallurgy (1973) 16, No. 31.
3. Hibbs, L.E. Jr. and Flom, D.G.: "Diamond Compact Cutter Studies
for Geothermal Bit Design, " ASME J. Pressure Vessel Technol. (Nov.
1978) 100, 406-16.
4. Giowka, D.A. and Stone, C.M.: "Thermal Response of Polycrystal-
line Diamond Compact Cutters Under Simulated Downhole Conditions,"
SPEJ (April 1985) 143-56.
5. Giowka, D.A. and Ortega, A.: "Frictional Heating and Convective
Cooling of Polycrystalline Diamond Drag Tools During Rock Cutting, "
SPEJ (April 1984) 121-28.
6. Giowka, D.A. and Ortega, A.: "Effects of Thermal and Mechanical
Loading on PDC Bit Life," SPEDE (June 1986) 201-14; Trans., AIME,
285.
7. Warren, T.M. and Armagost, W.K.: "Laboratory Drilling Perform-
ance of PDC Bits," SPEDE (June 1988) 125-35.
8. Winters, W.J.: "Roller-Bit Model with Rock Ductility and Cone Off-
set," paper SPE 16696 presented at the 1987 SPE Annual Technical
Conference and Exhibition, Dallas, Sept. 28-30.
9. Daniels, W.H. and Thompson, D.A.: "Fabrication and Laboratory Test-
ing of a Bit Containing Diamond Compacts," paper SPE 6713 presented
at the 1977 SPE Annual Technical Conference and Exhibition, Den-
ver, Oct. 9-12.

Nomenclature SI Metric Conversion Factors

Aw = cutter wear-flat area, in. 2 [cm 2] ft x 3.048* E-Ol m
f = thermal response function, (ft2-hr-OF)/Btu ft-Ibf x 1.355 818 E-03 kJ
[(cm 2 .°C)/W] in. x 2.54* E+OO cm
Fn = normal force on cutter, lbf [N] in. 2 x 6.451 6* E+OO cm 2
h = convective heat-transfer coefficient, Btu/(hr-ft2_0F) Ibf x 4.448222 E+OO N
convective heat [W/(cm2 . 0C)]
khf = rock thermal conductivity, Btu/(hr-ft- OF)
·Conversion factor is exact. SPEDE
[W/(cm 2 . 0C)] Original SPE manuscript received for review Sept. 27. 1987. Paper accepted for publication
Aug. 10, 1988. Revised manuscript received Oct. 10, 1988. Paper (SPE 16699) first
Kf = friction coefficient between rock and cutter presented at the 1987 SPE Annual Technical Conference and Exhibition held in Dallas,
Lw = wear-flat length, in. [cm] Sept. 27-30.

136 SPE Drilling Engineering, June 1989