Stepped Cutter Elements for Fixed Drill Bit Cutting Efficiency

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing fixed cutter drill bits face challenges in cutting efficiency and durability, leading to increased drilling time and costs due to frequent bit changes, which are influenced by the cutting efficiency of cutter elements and the exposed surface area of diamond during drilling.

Innovation Solution

The cutter elements feature a stepped cutting face with a primary and secondary cutting surface, designed to engage and shear the formation at different times, increasing the effective cutting area and enhancing drilling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single cutting surface is used on cutter elements, then the structure is simple, but the cutting efficiency is limited and the drill bit requires frequent changes

Engineering Contradiction:

Improvecutting efficiencyVSAvoiddrill bit lifespan

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The cutting face of each cutter element is segmented into multiple cutting surfaces (primary, secondary, and tertiary cutting surfaces) arranged at different angles and positions. This segmentation allows different portions of the cutter element to engage the formation at different times during rotation, effectively increasing the cutting efficiency and extending the usable life of the drill bit before cutter elements become worn out.

Inventive Principle:

Principle #1Segmentation

2Productivity

If multiple cutting surfaces are added to cutter elements, then cutting efficiency and lifespan are improved, but the device complexity increases

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidcutter element geometry

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple cutting surfaces are merged into a single integrated cutter element structure. The primary, secondary, and tertiary cutting surfaces are combined on one cutter element body, allowing the element to perform multiple cutting functions simultaneously as it rotates, thereby improving drilling efficiency without requiring separate cutter elements for each cutting stage.

Inventive Principle:

Principle #5Merging (Combining)

3Area of stationary object

If cutter elements engage formation at multiple points, then the effective cutting area increases, but the manufacturing complexity increases

Engineering Contradiction:

Improveeffective cutting areaVSAvoidcutter element fabrication

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The geometry of the cutter element is modified by changing parameters such as the angles and positions of multiple cutting surfaces relative to the cutter element body. By optimizing these geometric parameters, the effective cutting area is increased while maintaining manufacturability through standardized fabrication processes for the cutter element body and cutting surface configurations.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The stepped cutting face design improves cutting efficiency and extends the drill bit's lifespan by optimizing the engagement and shearing action, reducing the need for frequent bit changes and lowering drilling costs.

Implementation Method 1

each cutter element typically has a hard cutting layer of polycrystalline diamond or other superabrasive material

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

the rotating drill bit engages the earthen formation and proceeds to form a borehole

Methodology Applied

Scientific EffectFracture Mechanics: Fracture Mechanics

Implementation Method 3

drilling fluid is pumped through the drill string and directed out of the face of the drill bit

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 4

The drilling fluid flushes the cuttings removed from the bit face and from the bottom of the hole radially outward and then up the annulus

Methodology Applied

Scientific EffectFluid transport:

Implementation Method 5

the drilling fluid removes heat, caused by contact with the formation, from the cutter elements to prolong cutter element life

Methodology Applied

Scientific EffectConvection cooling: Convection

Data Source

PatentUS20260015913A1Fixed Cutter Drill Bits and Cutter Elements with Secondary Cutting Edges for Same

Publication Date: 2026.01.15 NAT OILWELL VARCO LP

AI summary

A cutter element for a fixed cutter drill bit configured to drill a borehole in a subterranean formation includes a base having a central axis, a first end, a second end, and a radially outer cylindrical surface extending axially from the first end to the second end. In addition, the cutter element includes a cutting layer fixably mounted to the first end of the base. The cutting layer includes a stepped cutting face distal the base and a radially outer cylindrical surface extending axially from the cutting face to the radially outer cylindrical surface of the base. The radially outer cylindrical surface of the cutting layer is contiguous with the radially outer cylindrical surface of the base. The stepped cutting face includes a first step, a second step axially spaced from the first step, and a riser axially positioned between the first step and the second step. The first step is axially positioned between the riser and the base.