Experimental study on shale-breaking of special-shaped cutter PDC bit

To enhance the drilling efficiency and extend the service life of PDC (Polycrystalline Diamond Composite) bits in shale formations, this study delves into the rock-breaking mechanisms of special-shaped cutters through a comprehensive experimental approach. This involves optimizing the cutter designs, conducting laboratory experiment and field testing. Among the various cutter geometries considered, concave, axe, planar, and triangular cutters are chosen as the focal points for unit rock-breaking experiments. These tests aim to assess their cutting loads and cutting specific energy to gain a deeper understanding of their performance characteristics. Based on experimental, the debris characteristics are analyzed. Based on the understanding of the shale-breaking characteristics of special-shaped cutters, field testing is performed using a novel PDC bit with a special-shaped cutter. Compared with planar cutters, the concave cutter and the triangular cutter generate lower cutting loads and cutting specific energy. Under identical conditions, the average cutting force and cutting specific energy of concave cutter at different cutting depths are reduced by 16.1% and 19.6% Specifically, the concave cutter generates the largest debris when operated under similar conditions, which is beneficial for increasing rock-breaking efficiency. Laboratory experiment indicate that compared to conventional drill bits, the novel drill bit experiences an increase in torque of approximately 9.8% with increasing WOB (weight on bit). Under high WOB, the ROP (rate of penetration) increases by about 75.4%, while the mechanical specific energy decreases by nearly 40%. Additionally, the novel bit vibration characteristics remain superior to conventional drill bits. Field testing shows that the average ROP of the novel bit and total footage drilled increase by up to 13.3% and 27.2%, respectively, in comparison with those for the conventional bit. The research results are helpful to speed up the efficiency of shale gas drilling. Through unit experiments and theories, the scratch characteristics, mechanical and microscopic changes of different cutting cutter and the characteristics of rock debris in the rock cutting process were analyzed.A full-scale drilling experiment system for special-shaped cutter drill bits was built. The cutting mechanical properties and vibration laws of the new drill bit were studied, and compared with the conventional drill bits.Through field tests, the drilling performance of the new drill bit under actual working conditions was tested compared with the conventional drill bit.The content of different experimental studies has deepened the understanding of the abnormal cutting and crushing process of shale. The research results are of great significance in promoting the development of shalerock-breaking tools.