Drill Bit Performance Improvements in Challenging North America Land Drilling Applications Through Optimization of PDC Cutter Technologies
Authors: Robertson A. , Hanafy A. , Valbuena F. , Gomez L. , Moulton H. , Tilleman D. , Ameri T. , Duffy S. , Bomidi J. 
Published: February 2025

Abstract
The continuous push for faster and longer bit runs in heavily directional, motor-oriented drilling applications requires Polycrystalline Diamond Compacts (PDC) cutters to better resist impact damage and abrasive wear while providing improved drilling performance. Moreover, drilling longer sections with interbedded lithologies requires PDC cutters to possess both high abrasion resistance and durability to resist dulling from the varied lithologies and overcome drilling dysfunctions inherent to such sections. This work will present optimized PDC cutters that enabled improved drilling performance in a variety of challenging applications.
This work details the optimization of PDC cutter technology by balancing the Polycrystalline Diamond (PCD) properties, PDC composite design, and cutting geometry according to an application's demands. Three applications are identified to showcase PDC cutter improvements in abrasion, impact, and general-purpose performance categories. Each application's typical dull was forensically analyzed to assess the appropriate design direction for improved PDC performance. PDC cutters were lab screened with a standard test protocol for assessing abrasion resistance and impact resistance. Cutting geometries were modelled via Finite Element Analysis (FEA) and cutting performance was verified with a pressurized single cutter rock cutting test. Each PDC cutter type was tested in the field against suitable offsets to confirm improvements in drilling performance and dull characteristics.
The optimized PDC cutters showed significant performance gains in terms of footage, rate of penetration (ROP), and dull grade across the performance spectrum. In lateral sections of Canada's Falher abrasive lithology, an abrasion-oriented PDC cutter improved drilling footage by 48% and 30% while also increasing the average ROP by 4% compared to offset runs. The Southeast USA Haynesville intermediate is challenged by high interbedding of hard, abrasive lithologies and high lateral vibrations induced by drilling dysfunctions. Here, a general-purpose PDC cutter combining high abrasion resistance and durability, and a novel cutting geometry optimized for drilling efficiency and durability drilled 32% further with equivalent ROP and better dull condition. In West Texas USA, lateral sections in the Leonard B formation are challenged with stringers that cause severe impact damage. An optimized impact cutter demonstrated 20% increased footage compared to offsets.
Optimization of the many facets of PDC cutter technologies proves effective in delivering drill bit performance in a variety of challenging applications. With the newly introduced cutters a higher footage per bit can be realized. Detailed analysis of the dysfunctions, lithologies, and operating conditions of a given application can further enable better PDC cutter designs and fruitful operating conditions.