Modeling of Cutting Rock: From PDC Cutter to PDC Bit—Modeling of PDC Bit

Abstract

Summary In this paper, we integrated our polycrystalline diamond compact (PDC) cutter model (Chen et al. 2021) into a PDC bit model that can predict the weight on bit (WOB), torque on bit (TOB), and imbalanced side force on a bit under given drilling conditions. We first proposed a method to determine the actual cutting plane and depth of cut of each cutter on a PDC bit. Once the two parameters for each cutter are determined, the cutter model can then be applied to calculate the cutting force of each cutter. The final bit force and moment (i.e., WOB, TOB, and imbalanced side force) are calculated as the resultant force and moment of cutting forces of all cutters. The PDC bit model in this paper considers all bit design parameters, including bit matrix geometry, blade profile, cutter layout, and the inclination of each cutter. Furthermore, the bit model also considers some bottomhole assembly (BHA) parameters (e.g., bit tilt angle, location of first fulcrum point, and tool face/steering plane angle), which allows the bit model to simulate a bit under different drilling modes. The bit model is also validated by published test data and field applications. Finally, case studies are conducted, and the influence of bottomhole stresses, BHA parameters, and drilling modes on bit force and moment are discussed. A field application of the bit model is also provided. The bit model can be directly used for PDC bit design and simulation. In fact, this paper presents a general way to integrate a cutter model into a PDC bit model. Readers are also encouraged to apply this method to integrate their own cutter model into a PDC bit model.