Multi-Step Depth of Cut Control for Drilling Tool Vibration
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Solution Overview
Problem
Conventional downhole drilling tools, such as PDC bits, experience uneven depth of cut control, leading to vibration and reduced drilling efficiency due to uneven wear and inadequate penetration rate control, as their depth of cut controllers (DOCCs) are not effectively configured to manage the varying compressive strengths of geological formations at different depths.
Innovation Solution
The design of a drilling tool with multi-step depth of cut control, where DOCCs are configured to control the depth of cut based on the location and orientation of cutting elements, overlapping the rotational path of the DOCCs, and using a method to determine the desired critical depth of cut, which is based on the rate of penetration and revolutions per minute, to provide a consistent and even depth of cut across the bit face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional DOCCs are used to control depth of cut, then the drilling tool can penetrate the formation, but uneven depth of cut control occurs leading to vibration and reduced drilling efficiency
Solution Approach 1:
The DOCC is divided into multiple depth of cut control surfaces, each configured to control the depth of cut for specific cutting elements at different radial positions. This segmentation allows each surface to be optimized for its specific zone, preventing uneven wear and vibration while maintaining consistent depth of cut control across all cutting elements.
Solution Approach 2:
Each depth of cut control surface is configured with specific geometry and positioning tailored to the local requirements of particular cutting elements. The control surfaces have different radial and axial positions, and different orientations, to match the specific needs of cutting elements at various locations on the bit face, ensuring uniform depth of cut control throughout.
2Manufacturing precision
If DOCCs are configured to control depth of cut for all cutting elements, then depth of cut control improves, but the complexity of determining optimal DOCC configuration increases
Solution Approach 1:
The patent introduces a systematic methodology that adds a new dimension to DOCC design by considering the rotational path of DOCCs and their overlap with cutting element paths. The method uses three-dimensional coordinate systems and geometric relationships to systematically determine optimal DOCC positions, reducing design complexity while improving precision.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and pre-configuring the DOCC surfaces based on desired depth of cut values before the drilling operation begins. The methodology determines optimal DOCC geometry and positioning in advance using systematic calculations involving cutting element locations, bit rotational speed, and desired penetration rates, eliminating the need for complex real-time adjustments.
3Adaptability or versatility
If cutting elements are used to drill through formations with varying compressive strength, then the bit can handle different formation types, but uneven wear occurs due to inadequate depth of cut control
Solution Approach 1:
The patent applies dynamics by configuring DOCC surfaces that can adapt to varying formation conditions through their geometric design. The control surfaces are positioned and oriented to maintain optimal depth of cut across different formation compressive strengths, allowing the bit to handle various formation types while distributing wear more evenly across cutting elements, thereby extending bit life.
Data Source
AI summary
In accordance with some embodiments of the present disclosure, a method of configuring depth of cut controllers (DOCCs) of a drill bit comprises determining a primary depth of cut for a first radial swath. The first radial swath is associated with a first area of the bit face. The method further comprises configuring a primary DOCC for placement on the bit face within the first radial swath based on the primary depth of cut. In addition, the method comprises determining a back-up depth of cut for a second radial swath. The second radial swath is associated with a second area of the bit face that overlaps the first area of the bit face associated with the first radial swath. The method further comprises configuring a back-up DOCC for placement on the bit face within the second radial swath based on the back-up depth of cut.