Virtual Drill Bit Testing With Digitized Rock Interaction Models

Solution Overview

Problem

Cutting elements in down-hole drilling operations face issues such as spalling, delamination, and fracture due to intense forces, torques, and temperature differentials, leading to reduced drill bit wear life and efficiency.

Innovation Solution

A digital rock lab is utilized for virtual testing and simulation, where digitized rock samples are modeled and simulated with cutting elements to generate digital rock interaction files, which are used to optimize drill bit design and performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If physical testing with real rock samples is used to test cutting elements, then the testing is accurate and reliable, but the process is time-consuming and expensive

Engineering Contradiction:

Improvetesting accuracyVSAvoidtesting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent creates digital twins (digitized rock samples) that are virtual copies of physical rock samples. These digital twins replicate the geological characteristics, structure, and properties of actual rock formations, allowing virtual testing of cutting elements without needing physical samples. This enables rapid iteration and testing while maintaining accuracy comparable to physical testing.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces physical mechanical testing systems with computational simulation systems. Instead of physically cutting and measuring rock samples in laboratories, the system uses computer models to simulate the cutting process, calculating forces, stresses, and material removal rates virtually. This substitution eliminates the time and cost constraints of physical testing infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If physical testing with real rock samples is used to test cutting elements, then the testing provides reliable data, but the cost of equipment and materials increases

Engineering Contradiction:

Improvetesting accuracyVSAvoidtesting cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent creates digital twins (digitized rock samples) that are virtual copies of physical rock samples. These digital twins replicate the geological characteristics, structure, and properties of actual rock formations, allowing virtual testing of cutting elements without needing physical samples. This enables rapid iteration and testing while maintaining accuracy comparable to physical testing.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces physical mechanical testing systems with computational simulation systems. Instead of physically cutting and measuring rock samples in laboratories, the system uses computer models to simulate the cutting process, calculating forces, stresses, and material removal rates virtually. This substitution eliminates the time and cost constraints of physical testing infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If cutting elements are made with super hard material layers to penetrate hard formations, then the cutting performance improves, but the risk of spalling, delamination, and fracture increases

Engineering Contradiction:

Improvecutting performanceVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent performs virtual testing and simulation before actual drilling operations to predict and prevent failures. By simulating cutting elements interacting with digitized rock samples under various conditions (high pressure, temperature differentials, abrasive forces), the system can identify potential spalling, delamination, or fracture risks before manufacturing and deployment. This allows for design optimization to prevent structural failures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses simulation results as feedback to optimize cutting element design and material selection. By analyzing the performance data from virtual testing, engineers can adjust the hardness, toughness, and layering of cutting elements to achieve the right balance between cutting performance and resistance to spalling and delamination. This iterative feedback loop ensures structural integrity while maintaining high cutting performance.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12481804B2Cutter and drill bit design by virtual testing with digitized rocks

Publication Date: 2025.11.25 SCHLUMBERGER TECH CORP

AI summary

A method for designing a drill bit includes simulating a cutting element cutting a digitized rock sample, storing outputs from the simulating in a digital rock interaction file, modeling the drill bit to have at least one of the cutting element, and using data in the digital rock interaction file to simulate the drill bit in a drilling operation.