Drill Bit Notes
Drill Bit Notes
1
July 2002
The text in normal font is a typical monologue that might accompany this
presentation. We strongly recommend that you use this only as a guide to the
principle points that are to be made. Do not attempt to read from it in the
presentation or to memorise it. Work out your own way of presenting the
concepts using your own words.
The text in bold letters offers suggestions for ways of handling questions, or
provides background information……
The symbol - Î - instructs you to advance to the next slide or the next build on
the current slide.
Version 2.4 1
Introduction to Drill Bits July 2002
Drill Bits
An Introduction
Prepared By:
Ian McMillan
Version 2.4 2
Introduction to Drill Bits July 2002
Failure Mechanisms
– Shear Failure PDC BIT
CONTINUOUS
SHEARING
– Compressive Failure
3
July 2002
Rocks fail, generally, by one of two failure mechanisms. The first of these is shear
failure. This is similar to the scraping of butter with a knife. Sheer failure is typical of
the drilling mechanism employed by PDC bits. The Drilling action is continuous. Î
The second kind is compressive failure. This is comparable to chipping at rock with a
chisel.
Compressive failure, which is common in hard formation insert bits, is discontinuous,
but cyclic.
It is common for there to be a combination of these two failure modes within a
specific application. Î
Version 2.4 3
Introduction to Drill Bits July 2002
Rock Strength
• Shear Strength
• Compressive Strength
4
July 2002
Ask the class which of the two failure mechanisms is the more efficient. Ask them
why they have given the response they have.
For most rock types the compressive strength of the rock is approximately double
that of the shear strength. Î
This means that for the same application of energy, in terms of the weight on bit and
rotary speed, that a rock will fail twice as easily by shear as it will through
compression. Consequently the rate of penetration when the rock is failed through
shear will typically be double that which is found when the rock fails through
compression. Î
(We often see that the rate of a Penetration for a fixed cutter bit is roughly
double that for a roller cone bits, assuming that this is an application
appropriate for a PDC bit. These are general rules, however. It is not unusual to
find the roller cone bit drilling as fast or faster than a fixed cutter bit under
specific circumstances. In these cases the rate of penetration is being
controlled by factors other than the failure mechanism of the rock.)
Version 2.4 4
Introduction to Drill Bits July 2002
Drilling Mechanisms
Those are the two failure mechanisms of rock. Let us see how they translate into
drilling mechanisms. Î
Version 2.4 5
Introduction to Drill Bits July 2002
Drilling Mechanisms
• Pure Shear Failure
6
July 2002
In in the early days of rotary drilling this was the type of bit that was used. This is a
simple drag bit, made of steel, that drills by pure shear failure.
This was an efficient way to drill the rock, in that it generated high R.O.P., but was
inefficient in that the steel was not very durable. It was soon supplanted, in the early
part of the 20th century, by roller cone bits. Î
Version 2.4 6
Introduction to Drill Bits July 2002
Drilling Mechanisms
• Compressive and
Shear Failure
7
July 2002
With many of these there is a significant blend of compressive and shear failure. This
is true of soft formation milltooth bits: the tooth first penetrates the formation by
overcoming the compressive strength of the rock; then, as the cone rotates, the
tooth scrapes the formation, overcoming its shear strength. Î
Version 2.4 7
Introduction to Drill Bits July 2002
Cutting Elements
• Teeth and hardfacing
8
July 2002
We will digress briefly as we move through the different drilling mechanisms and
their associated bit types, to consider the cutting elements of the bits.
The teeth are milled out of a solid steel cone. This steel is not especially durable.
(You will recall that was the problem that affected the drag bit.) We can overcome
this weakness, to a degree, by welding a hardmetal, hardfacing, onto the teeth. This
covers all, or much, of the teeth and is very wear resistant. This durability arise from
the tungsten carbide particles that form the active part of the hardfacing. (Point
these out in the cross section.)
This hardfacing greatly extends the life of the bit, by keeping the cutting structure
sharp for longer than would be the case with unprotected steel teeth. Î
Version 2.4 8
Introduction to Drill Bits July 2002
Drilling Mechanisms
• Compressive Failure
9
July 2002
Insert bits designed for drilling very hard formation use almost pure compressive
failure. They chip and fracture the rock in order to drill. The insert impacts the
formation, creating a small crater and generating a series of fractures that spread
out from this crater. This creates a group of rock chips that can then be displaced by
the next impacting insert or by mud flow. Î
Version 2.4 9
Introduction to Drill Bits July 2002
Cutting Elements
• Tungsten Carbide Inserts
10
July 2002
The inserts are made from tungsten carbide and are pressed into holes drilled in the
steel of the cone, where they are held by compression fit. The shape and size of the
inserts is varied according to the application.
In aggressive insert bits, with long inserts, such as that on the left, a combination of
compressive and shear failure is most likely. Î
Version 2.4 10
Introduction to Drill Bits July 2002
Bearing Type
Roller Friction
11
July 2002
We have been talking about roller cone bits. There are some other terms that are
used. These terms are alternatives. We may call a roller cone bit a rock bit, or a
rolling cutter bit. Be cautious in the use of the term Tricone bit. This is a Hughes’
trademark and should not be used in writing unless referring specifically to Hughes
product. Î
We have seen that there are two cutting structure types: milltooth and insert,
sometimes referred to as tooth and TCI. Î
There are also two different types of bearing: roller bearing and friction bearing.
Note the potential confusion between roller cone bits and roller bearing bits. All
roller bearing bits are roller cone bits. Roller cone bits may be roller bearing, but they
might also be friction bearing. Î
Version 2.4 11
Introduction to Drill Bits July 2002
Bearing Types
• Roller Bearing
Usually
sealed,
but may be
unsealed.
12
July 2002
What is a roller bearing? Its key feature is the presence of rollers within the bearing
assembly. (Point out the roller races on the diagram) As load is applied to the bit,
it is transmitted from the inserts or teeth, through the cone shell, then through the
rollers, to the main bearing or journal.
Point out the ball bearings and ask the class what their function is.
The ball bearings are what holds the cone on the journal. They are the cone
retention mechanism. Î
An important aspect of roller bearings is the way the load is transmitted through the
rollers. The load is not applied over a wide area, but along a line running the length of
the roller. As the rollers rotate within the assembly,as the bit turns, the line loading
moves. This means that the surface of the journal is subject to cyclic loading at high
weights and high frequency, for an extended period of time. This can lead to fatigue
failure, and is one of the failure modes of this bearing design.
Failure can also occur because of wear from solids, especially abrasive solids, that
enter the bearing assembly. Î
To counter these, the bearing may be sealed. (Point out the location of the seal on
the diagram) Î
Version 2.4 12
Introduction to Drill Bits July 2002
Bearing Types
• Friction or Journal Bearing
Always
Sealed
13
July 2002
Version 2.4 13
Introduction to Drill Bits July 2002
Cutting Elements
• Shear revisited -
– Polycrystalline
Diamond Compact
14
July 2002
You will recall that the simple steel drag bit could drill rapidly, but not for very long.
The introduction of PDC bits in the late 1970’s brought the necessary durability to this
efficient rock failure mechanism. Î
This durability arose from the character of the very hard artificial diamond in the PDC
cutters - Polycrystalline Diamond Compact. Î
The diamond layer, formed from many artificially created diamond crystals, is
bonded to a tungsten carbide substrate at very high pressures and high temperature
Î in this device. Î
The PDC element is then further bonded to a longer tungsten carbide post or
cylinder. This makes it easier to fix the PDC within the body of the bit. Î
The end result looks like this. Î
Version 2.4 14
Introduction to Drill Bits July 2002
Cutting 19 mm
16 mm
13 mm
Elements 11 mm
8 mm
15
July 2002
Version 2.4 15
Introduction to Drill Bits July 2002
Drilling Mechanisms
• Shear Failure
PDC BIT
CONTINUOUS
SHEARING
16
July 2002
This bit will drill, primarily, by overcoming the shear strength of the rock, which, as
we have seen is an efficient way of drilling that can generate high R.O.P. This, then,
is the commonest of fixed cutter bits, the PDC bit. Î
Version 2.4 16
Introduction to Drill Bits July 2002
Drilling Mechanisms
• Shear/Compressive
Failure
NATURAL DIAMOND
OR IMPREG BIT
CONTINUOUS
CRUSHING
17 & ABRASION
July 2002
The diamond bit is an old design concept. It drills through a combination of shear and
compressive failure occurring at a small scale, almost at a microscopic level. The
diamonds embedded in the body of the bit abrade and crush the formation. Î
Version 2.4 17
Introduction to Drill Bits July 2002
Cutting Elements
• Natural Diamonds
– Size
– Shape
– Quality
18
July 2002
The cutting elements are generally natural diamonds. The size, shape and quality
may be selected based upon the character of the application. In each case the
diamond is embedded in the surface of the blades of the bit. Once the diamond is
worn or lost the bit is dulled. Î
Version 2.4 18
Introduction to Drill Bits July 2002
Cutting Elements
• Impregnated Diamond Blades
19
July 2002
Version 2.4 19
Introduction to Drill Bits July 2002
Cutting Elements
• TSP (Thermally Stable PDC)
20
July 2002
We can see TSP blocks used in this impregnated diamond bit example to give the bit
drilling properties that allow it to drill out float collars etc. Î
Version 2.4 20
Introduction to Drill Bits July 2002
STEEL BLANK
TUNGSTEN
CARBIDE
MATRIX
Matrix Body
21
July 2002
The impregnated diamond bits we have just considered have a body that is formed in
a mould. A similar technique is used for manufacturing PDC bits with matrix bodies.
The mould has blanks occupying the positions of cutters and nozzles, Î while TSP
gauge protection is placed by hand. Î A steel blank fits partially into the mould,
which is then filled with powdered metal. Î Binder mixture is added above and Î
the whole is heated within a furnace. The binder fuses the matrix material together
and to the steel blank.
A steel pin, of suitable mechanical properties, is then welded to the steel blank.
(Point out the pin on the top right diagram.)Î
Version 2.4 21
Introduction to Drill Bits July 2002
Steel Body
22
July 2002
The alternative body material is steel. The steel bit is manufactured from a single
block, on multi-axis computer controlled lathes and drills. Steel bodies can be
manufactured more rapidly than matrix, they are less expensive, they can be made
shorter (because no blank is required) giving better directional response, but they
are less erosion resistant. Î
Version 2.4 22
Introduction to Drill Bits July 2002
Drilling Mechanisms
z Gouging & Scraping Milltooth
z Shearing PDC
23
July 2002
In summary, then, drill bits drill by a variety of mechanisms, but these are
combinations of the two basic rock failure mechanisms, compressive failure and
shear failure. Î
These different mechanisms are associated with particular bit types. This is an
association, not an exclusive arrangement. In a hard formation, tooth bits will drill
primarily by compressive failure, with little or no shearing action. Soft formation
insert bits are like milltooth bits in that they use a combination of the two. Some
recent designs of impregnated bits drill the soft formations largely by shear.
Compressive failure is an important aspect of drilling in chalk with fixed cutter bits,
and so on. Î
Version 2.4 23
Introduction to Drill Bits July 2002
Bit Classification
A Broad Overview
We have looked at the rock failure mechanisms and the associated drilling
mechanisms, now let us summarise what this means in terms of bit classification. Î
Version 2.4 24
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P. Diamond
Diamond
25
July 2002
Version 2.4 25
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
26
July 2002
First we have the fixed cutter bits including PDC bits in all their variety. Î
Version 2.4 26
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
27
July 2002
Then there are the diamond bits, beginning with natural diamond. Î
Version 2.4 27
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
28
July 2002
There are TSP bits where the cutting elements are composed of blocks of TSP, the
thermally stable form of polycrystalline diamond. Î.
Version 2.4 28
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
29
July 2002
Here are impregnated diamond bits, where the diamond grit is distributed
throughout the blade. Î
Version 2.4 29
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Rock Bit
Tri-Cone P.D.C. Diamond Milltooth Insert
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
30
July 2002
Then we move from fixed cutter to roller cone bits, or as they are also known rock
bits or tri-cone bits. Î
Version 2.4 30
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
31
July 2002
There are two cutting structures here. The milltooth bit, with its teeth milled from the
cone shell and protected by welded hardmetal, .. Î
Version 2.4 31
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
32
July 2002
And the insert bit, with tungsten carbide elements pushed into holes in the cone
shell.
Each roller cone bit has bearings which maybe one of two types. Î
Version 2.4 32
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
33
July 2002
Roller bearings are characterised primarily by the presence of rollers as part of the
load bearing mechanism. Î
Version 2.4 33
Introduction to Drill Bits July 2002
Bit Classification
Drill Bits
Fixed Rolling
Cutter Cutter
Roller Friction
Natural Impregnated Bearing Bearing
T.S.P.
Diamond Diamond
34
July 2002
In friction bearing bits the contact between cone and journal is direct or nearly so.
Either bearing type may be used with either cutting structure. Î
Version 2.4 34
Introduction to Drill Bits July 2002
Bit Classification
To assist in the comparison of bits from different manufacturers the IADC introduced
a coding system for roller cone bits, and later for fixed cutter bits. Î
Version 2.4 35
Introduction to Drill Bits July 2002
IADC Codes
Roller Cone Fixed Cutter
• 5-1-7 • S222
• 1-3-5M • M419
• 1-1-1 • S313
• 8-3-7X
36
July 2002
These are typical examples of these codes. At this point we shall examine the first
two digits of the Roller Cone system only. Î
Version 2.4 36
Introduction to Drill Bits July 2002
Tooth
1-1
Soft
1-3
2-1
3
37
July 2002 Hard
The first two digits of the system focus upon the of the kind of formation the bit is
designed to drill. Î
So, a tooth bit designed for the softest formations would be considered a series 1 bit.
Î
Bits suitable for intermediate formations would be series 2. Î
And those designed for the hardest, most abrasive formations, would be series 3. Î
Each series was sub-divided. Thus, the softest of formations would be drilled with a 1
- 1, while a somewhat harder formation would be drilled Î
With a 1 - 3, and harder still Î
With a 2 - 1. And so on. Î
Version 2.4 37
Introduction to Drill Bits July 2002
Teeth Inserts
Soft 4-1
4
2
5
6
7
3 8-3
38 8
July 2002 Hard
A similar arrangement applies to insert bits. Those designed for the hardest
formations are series eight, and are similarly subdivided into 8 -1, 8 -2, 8 -3, 8 -4. Î
Bits for somewhat softer formations have more aggressive cutting structures. Î
The drill bit industry, in the early days of insert manufacture, was unable to
manufacture inserts with aggressive shapes, that did not break. As the technology
improved we were able, as an industry, to make increasingly more aggressive
designs. Î
Thus the most aggressive insert design can compete with milltooth bits in all but the
very softest formation. Î
Version 2.4 38
Introduction to Drill Bits July 2002
Teeth Inserts
Soft
2 4
2
3 5
6
7
3
39 8
July 2002 Hard
Today it is very unusual to see series 2 or series 3 toothed bits in use for drilling
significant intervals. That gives us an arrangement like this. Î
Version 2.4 39
Introduction to Drill Bits July 2002
Teeth Inserts
Soft
1 1-3
2 4
3 5
6
4-1
7
40 8
July 2002 Hard
If a cutting structure harder than a 1-3 is required, typically we will move to a series
4, or higher, insert bit. Î
Version 2.4 40
Introduction to Drill Bits July 2002
Soft
2 4
3 5
6
41 8
July 2002 Hard
There is an IADC code for fixed cutter bits, but in this is not in as common use as that
in for roller cone bits. Nevertheless it is useful to see where the fixed cutter bits are
positioned in relation to rock hardness. Î
The natural diamond bits drill the hardest of formations, equivalent to series 7 and 8
insert bits. Î
Version 2.4 41
Introduction to Drill Bits July 2002
Soft
2 4
3 5
6
42 8
July 2002 Hard
As technology advanced to they were able to drill in harder and harder applications.
Î
Version 2.4 42
Introduction to Drill Bits July 2002
2 4
3 5
6
43 8
July 2002 Hard
Impregnated bits can match the hard applications of natural diamond bits, but with
some designs are able to drill softer formations, so that they may overlap with heavy
set PDC bits or intermediate insert bits.
The result of these continual advances in technology is it that the Drilling Engineer
has a wider range of bit types available to him. In soft formations his choice may be
between tooth, insert or a light set PDC. In very hard formations he has available
button insert bits, natural diamond bits and impregnated diamond bits. In
intermediate formations, that a few years ago could have been drilled only with an
insert bit, he may now have the further options of heavy set PDC or aggressive
impreg designs. Î
Version 2.4 43
Introduction to Drill Bits July 2002
Mill Tooth
Insert
Impreg
& N.D.
44
July 2002 Formation Compressive Strength
DP
Let us look at how these different bit types perform in terms of Rate of Penetration,
set against the rock strength. Î
Fixed cutter bits drill the softer rocks and do so at a high R.O.P. Î
Milltooth bits cover a similar range of rock strengths, but are generally slower. Î
Insert bits cover a much wider range of rock types, though they tend not to be used
for the very softest, and are typically somewhat slower than toothed bits. Î
Diamond bits are restricted to the hardest of rock types and are correspondingly
slower. Î
Version 2.4 44
Introduction to Drill Bits July 2002
Bit Classification
Version 2.4 45
Introduction to Drill Bits July 2002
Advantages
• Very Fast ROP
• Long Life Potential
Considerations
• Impact Damage
• Abrasiveness
• Stability
46
July 2002
DP
Discuss the strengths and weaknesses of each bit type. Use this opportunity to
tie together all the points that have been presented so far, and address
questions that were raised, but perhaps not fully answered. Hammer home the
key features of each bit and of rock failure mechanisms and drilling
mechanisms. Adapt what you say to the background and interest of the class
as revealed in their questions, or absence of questions. Î
Version 2.4 46
Introduction to Drill Bits July 2002
Tooth Bits
Advantages
• Fast ROP
• Good Stability
• Economic
Considerations
• Tooth Wear Rate
• Bearing Life
47
July 2002
DP
Carry on as, for the previous slide. Summarise, Emphasise, Hit Them Between
the Eyes. Î
Version 2.4 47
Introduction to Drill Bits July 2002
Insert Bits
Advantages
• Cutting Structure Durability
• Range of Formations
• Interbed Tolerance
• Steerability and Stability
Considerations
• Slower ROP
• Bearing Life
48
July 2002
DP
Version 2.4 48
Introduction to Drill Bits July 2002
IMPREG and
Natural Diamond Bits
Advantages
• Very Durable
• Hard Rock Capability
• Low Junk-in-Hole Risk
Considerations
• Slower ROP
• RPM Sensitivity
• High Cost Applications
49
July 2002
DP
Version 2.4 49
Introduction to Drill Bits July 2002
Conclusion
Questions?
Ask for questions. Clarify points that they should now have a grasp of. For
questions that relate to material to be dealt with later in the course give a brief
answer now and note that you will be dealing with the matter in more detail
later.
Take a break!
Version 2.4 50
Introduction to Drill Bits July 2002
Version History
• Version 1.0 This presentation was created in its initial form in Q1 2001
for use on D & M Directional Driller Induction Courses
• Version 2.2 Minor editing to the notes and animations, plus the addition
of some slides on IADC codes, was carried out in August 2001
• Version 2.3 Two slides added on PDC body material – November 2001
• Version 2.4 All roller cone slides replaced by ‘blue bit’ versions. Minor
alterations to Notes pages text.
Version 2.4 51
Introduction to Drill Bits July 2002
Acknowledgements
• Version 2.1
– My thanks to Mark Jordan for reviewing this material.
• Slides 48, 50-53 and illustrations in slide 7 are from
material created by Tom Wick and David Pearce.
• Most bit and component photographs are from the CD-
Lite for fixed cutter bits and the Electronic Reference
Guide for roller cone bits.
52
July 2002
Version 2.4 52
Introduction to Drill Bits July 2002
53
July 2002
Version 2.4 53
Introduction to Drill Bits July 2002
Contact Information
If you have any questions concerning the contents of this presentation contact:
Ian McMillan
Reed-Hycalog,
Kirkton Avenue,
Dyce,
Aberdeen
AB21 0UB
e-mail:
54 [email protected]
July 2002
Version 2.4 54