Investigation on the rock-breaking performance of specially-shaped PDC cutter under confining pressure conditions

Cutter shape has a significant influence on the rock-breaking performance of drill bit. Compared with conventional Polycrystalline Diamond Compact (PDC) cutter, the emergence of specially-shaped PDC cutters (SSPCs) with different geometric shapes is of great benefit to solve the problems of low rate of penetration (ROP) and rock-breaking efficiency in deep hard and hot dry rock formations. However, the high confining pressure and high in-situ stress (HCHS) have a significant influence on the rock-breaking performance of PDC cutter which cannot be ignored. Given that the above facts, this paper selects five kinds of PDC cutters with different cutter shapes, and implements a series of cutting experiments of granite under confining pressure conditions (CPCs) and atmospheric pressure condition (APC) using a true triaxial rock cutting device. The influence of cutter profile on the rock-breaking performance of PDC cutter was studied from the perspective of cutting force, mechanical specific energy (MSE), cuttings, coarseness index (CI) and fractal dimension. The results show that the rock breaking under CPC is more difficult than that under APC, resulting in the increased cutting force and MSE. Moreover, the cuttings obtained under CPC are smaller in size and the cutting grooves are smoother. Cutter shape has a great influence on the rock-breaking efficiency of PDC cutter, the rock-breaking efficiency of axe-shaped cutter is higher, while that of stinger cutter is lower. Moreover, PDC cutters with different shapes have different sensitivities to confining pressure, and stinger cutter has the lowest sensitivity to confining pressure, in other words, confining pressure has little influence on the rock breaking process of stinger cutter. What is more, the distribution of cuttings is characterized by the fractal dimension and particle size distribution parameter from the perspective of cuttings morphology and size respectively, and they present completely opposite changing trends. The obtained results are of great significance to the optimization of cutter profile, the design of bit cutter arrangement and the drilling of deep formation.