Effect of Back Rake Angle and Shape of PDC Cutter On Wear Rate In Hard Formation

This project aimed to investigate the effect of cutter back rake angle and shape of cutter on Polycrystalline Diamond Compact (PDC) cutter wear rate in hard formation application. PDC bits are widely used to drill soft formations in petroleum industry due to their excellent Rate of Penetration (ROP). Conventional PDC bits often failed in hard formations due to the formation abrasiveness and impact load damage. Advancements in cutter technologies by enhancing the high wear and impact resistance helps to expand the PDC bit application. The study is focused on the single cutter test using 16mm PDC cutter. The drilling operation is carried out in granite formation under constant applied force and velocity. The theoretical basis of the PDC cutter is studied using the cutter-rock interaction model and Merchant’s cutting model. A 3D simulation model of rock breaking using a single PDC cutter is established with Finite Element Method (FEA) based on elastoplastic mechanics and rock mechanics to analyze the stress beneath the cutter. The FEA model of the single cutter test is simulated using ABAQUS software. Effect of back rake angle and shape of PDC cutter on the rule of cutter wear rate are analyzed by using the wear theory. Result showed that ac ra e ang ed cutter and beveled-shaped cutter are the best design to minimize the cutter wear rate in hard formation.