3D Simulation Workflow for Performance of Sharp and Worn PDC Drill Bits

Abstract This paper describes the development of an improved polycrystalline diamond cutter (PDC) drilling performance simulation in 3D which includes worn cutters. A polygonal mesh model is used to improve the geometric data needed for the drilling performance model calculations. Methods for active face identification have been developed to consistently identify a variety of polygonal face types. The simple wear flat definition used for data input is shown to adequately capture the geometry compared to field worn bit scans and provide valuable insights with active face identification. Drilling performance calculation and results from the calibration to laboratory drilling data and validation to both laboratory and field data are shown. Additionally, including a velocity parameter in the drilling performance model reduced model error.