05 - Cutter Layout

Fixed Cutter Bit Design Manual
Cutter Layout
This document remains the property of Halliburton DBS and must be returned upon request
Date: June 1,2015 Initial By Assignee: ________

Cutter Layout
In the design process, cutter layout and manipulation is the last aspect of cutting structure
design that will determine a bits aggressiveness and durability. In cutter layout the
designer determines the cutter orientation and placement along the cutting tip profile
which will dictate the overall bit behavior. This will be the point that the designer may
have the most affect on the bits efficiency. With the development of the cutting analysis
tools cutter layout becomes an analytical process based on the Designers experience and
knowledge of the applications.
Single Set
Philosophically, FM2000 products would start as Trac-Set and move towards single set
as improved efficiency was required. FM3000 should start as single set to optimize
efficiency and move to trac-set as improved stability is required. We believe the
significant improvements in cutter integrity, improved understanding and implementation
of blade and gage pad spiral, and the improved understanding of Energy and Force
balancing reduces the need for trac-setting.
A single set cutting structure is defined as having no cutters in the same radial or
longitudinal position. Each cutter is labeled numerically in IBits starting from the center
of the bit and progressing towards the gage.
One of the major contributors to single set cutting structures efficiency is the limited
shear length of the cutter (the length of formation which is actually being sheared away
from the in situ rock, this is the bottom edge of the engagement area).

As the shear length decreases so does the torsional energy required to fail the formation.
Also, the indention width of the cutter is much smaller for single set cutting structures
which translates into lower required WOB’s to penetrate the rock for any given ROP.
Although the single set cutting structure is the most efficient, it is also the least stable and
susceptible to lateral vibrations.
The above diagram depicts the engagement area (portion of the cutter face engaged in the
formation shown in black) and force distribution curves for a single set cutter. The
grooves created by the cutters in this type of design define a narrow cutter engagement
and corresponding force distribution curves as shown on the drawing on the left. The

forces are broken down into their radial and vertical components. The drawing on the
right shows what happens when the bit attempts to move laterally from its established
bottomhole pattern (in this case to the right 0.025”). In this particular example a net
radial force is acting in the direction of offset. This type of force tends to perpetuate the
lateral vibration tendencies and reinforce bit whirling motion. Design features including,
continuous blade and gauge pad spiral, F.A.S.T., and Energy Balancing will combat the
trade-off of stability for FM3000.
The following chart gives a general

overview of the trade-off of
efficiency and stability. Single-set
bits have the highest drilling
efficiency, or aggressiveness, but
the lowest stability. TRAC-LOCTM
bits have the lowest drilling
efficiency, but the highest stability.
Various degrees of redundancy are
between these two extremes. These
relationships are confirmed by
testing done at Terra-Tek in
December 2000. A single set
scribe bit was the most efficient followed by a Brussels SE3000, Single-Set round, Track-
Set opposing and Trac-Set trailing designs respectively while drilling Carthage
Limestone.
Bit Cutting Efficiency

BP/SDBS Terra-Tek December 2000
0.4
0.35
SS-Scribe
Cutting Efficiency
SE3000
TST
0.3
TSO
SS-CH
SS-UNCH
0.25
60 RPM 210 60 60 210 60

12k WOB 12k 12k 18k 18k 18k
0.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Data Point Number
Track Set and Trac-Loc


Security DBS has utilized redundancy or track setting for several years with significant
success in limiting impact damage to cutters by providing bit stability. Redundancy
entails the use of two or more cutters at exactly the same radial and longitudinal position
but on different blades. In this way a bit can have exactly the same number of cutters but
with far fewer profile view positions. Cutters are labeled in IBits with a combination of
numbers and letters according to radial position and redundancy. Numbers increase from
center to gage for each unique radial location a cutter or group of cutters occupies.
Letters identify groups of cutters in the same radial location.
Although redundant set bits have been around for quite some time, we began seriously
investigating their benefits as we were developing TRAC-LOCTM cutting structures
(which entail the extreme version of redundancy where there is one primary blade and all
other blades are redundant to it). An example of TRAC-LOCTM is shown below.

We found that TRAC-LOCTM cutting structures were extremely stable, but also extremely
inefficient (high WOB necessary for given ROP).
The above diagram depicts the engagement area and force distribution curves for a
TRAC-LOCTM cutter. The grooves created by the cutters in this type of design define a
wide cutter engagement and corresponding force distribution curves as shown on the
drawing on the left. As the bit attempts to move laterally from its established bottom
hole pattern (offset to the right 0.025”), a large force is generated which pushes the cutter
back to its original bottom hole groove. This “restoration force” occurs across the entire
bit face when lateral vibrations are initiated down hole (as in bit whirl).
1000
This restoration force has been confirmed

Sierra White Granite
through single cutter testing at Sandia National
100
Tennessee Marble Laboratories. The graph on the left displays
Restoring Force, F
restoration forces for a 13mm TRAC-LOCTM

(lb)
cutter in several rock types. Note that the scale

Berea Sandstone on the left is logarithmic.
10
This simple study reinforces what we have seen

in the field and laboratory testing, the TRAC-
LOCTM cutting structure combats lateral
1
0.00 0.01 0.02 0.03 0.04
vibrations. TRAC-LOCTM, however, is inefficient
Offset Distance, OD in its cutting action for several reasons. The
(inch)
shear length is much longer and the indention
width is much wider on the TRAC-LOCTM cutter. And, for TRAC-LOC cutters the uncut
bottom (the formation ridge between the cutters that does not get cut and is removed only
by the bit body) requires significant WOB to remove. These inefficiencies have been

verified through single cutter testing at Sandia National Laboratories, and full bit testing
at Terra Tek.
Utilizing redundancy, but not to the extreme case of TRAC-LOCTM, was seen as a way of
generating some restoration forces to combat bit whirl without create the significant
inefficiencies of TRAC-LOCTM. The diagram below shows the engagement area and
force distribution for a track-set cutter.
Again, these trends have been confirmed through single cutter testing. The following
graphs show drag and penetrating forces for cutters at various Groove Depths in three
rock types. Note in the weaker rock (Berea Sandstone) that the inefficiencies are not as
prominent.

Track setting can take many forms, dependent on the number of blades and proposed
application of the bit. A redundant layout is usually noted for the number of blade
“starts”. TRAC-LOCTM is called “one-start” because there is one primary blade and all
other blades are redundant to this one. Similarly, “two-start” would denote two primary
blades and all other blades redundant to either one of these two. By knowing the total
number of blades, you can define the total number of primary and redundant blades on
any given bit. For example, a seven-bladed bit, which is “three-start”, would have three
primary blades and four redundant blades.
We have utilized both trailing (redundant blade directly following its primary blade) and
opposing (redundant blade approximately 180 degrees from its primary blade)
redundancy. Lab testing has shown that cutting efficiency from high to low is single set,
track set opposing, track set trailing, and then Trac-Loc™ layouts.
Examples on the following pages show typical track setting characteristics.

One Start Redundancy (TRAC-LOCTM): Cutter positions were determined on B1.

B2-B6 are redundant to B1. This is shown by the R1 label.
Two Start Redundancy (Trailing): Cutter positions were determined on B1 & B4.
B2 & B3 are redundant to B4. B5 & B6 are redundant to B1.

Three Start Redundancy (Opposing): Cutter positions determined on blades B1,

B3 and B5. B2 is redundant to B5. B4 is redundant to B1. B6 is redundant to B3.
Three Start Redundancy (Trailing): Cutter positions determined on blades B1, B3

and B5. B2 is redundant to B3. B4 is redundant to B5. B6 is redundant to B1.

Four Start Redundancy (Trailing): Cutter positions determined on blades B1, B3,
B5 and B7. B8 is redundant to B1. B2 is redundant to B3. B4 is redundant to B5.
B6 is redundant to B7.
Single Set: Cutter positions are determined on blades B1, B2, B3, B4 and B5. All
cutters have unique positions in the profile view.
Density
Increased cutter density lowers a bit’s aggressiveness and increases its durability. FM
cutter layout is done through the definition of zones of cutter clearance. This method is
somewhat intuitive and can lead to inconsistent wear patterns that have to be adjusted
through an iterative layout process. In practice, cutters in the cone region are set with a
gradually decreasing clearance and maximum set (minimum cutter clearance) is achieved
at some point before the bit nose.

Attention to dull bit wear patterns can further refine the cutter density. The philosophy
is, to minimize the number of blades and the profile length while maintaining the desired
cutter density. Minimizing blade count dramatically enhances cleaning, while
minimizing profile length generally increases the bit’s aggressiveness. It should be noted
that these are general rules and some applications may require alternative philosophies.
There are several methods to study the density trend, including looking at cutter forces or
work rates plotted along the cutter profile. In IBits, we can look at these trends by
studying the wear value graph. Wear values are a simple way of looking at relative cutter
wear rates. Wear graph numbers are generated through an integration technique which
computes the diamond area at a given integration step divided into the square of the
cutters radial position from the bit centerline. Once you have become familiar with the
general shapes of these curves, this is a helpful tool to identify weak points in the cutter
density and even compare cutter densities of two similar bits.

Some examples are:
Example 1: Wear Value and Diamond Quantity graphs should show relatively
consistent trends from centerline to gage. One peak generally occurs around the
profile nose with slight increase at gage. You should also be able to see where
secondary blades begin. The key here is to eliminate significant spikes in the
graphs which would identify weak areas.

Example 2: A sharp peak in the wear value and a dip in diamond quantity show a
weakness in the cutting structure. This cutting structure should be redone.
Example 3: Generally Trac-Set or Trac-Loc bits will exhibit sharp peaks in the overall
wear graph. This is the only time that peaks of this nature are acceptable.
Back Rake and Side Rake Angles

Back rake and side rake angles orient the cutter about its cutter center defined in 3D
coordinates. Once the number of blades, profile, and cutter spacing is established, cutter
back-rake becomes the dominant factor in achieving the preferred aggressiveness or
durability. Side-rake has less affect on aggressiveness and durability and is more
generally used to blend the cutter faces.
Back rake and side rake angles are generally defined relative to the cutter profile. In
other words, the back rake is given relative to a line perpendicular to the cutter profile
through the center of the cutter. Side rake is given relative to a line parallel to the profile
tangency through the center of the cutter.

Cutter position and rake angles
Cutter position and absolute rake angles
The optimum back rake angle in terms of simple drilling efficiency has been found to be
in the range of 17 or 18 degrees in laboratory single cutter tests. This, of course, does not
take into account the impact strength necessary for cutters drilling in vibrating down hole
conditions, or varying rock strengths. In general, increasing back rakes above 15 degrees
increases impact and wear resistance but decreases drilling efficiency. Low back rakes
can be used more readily in softer formations where impact damage is not as prevalent.
We have found that variable back rakes across the bit profile can enhance drilling
performance. Drilling slope, cutting efficiency, and susceptibility to impact damage are
the three variables that should be considered when determining the desired back-rake
scheme. Cutters in the cone generally have a low susceptibility to impact damage but
due to their significant formation engagement will typically see the highest forces. It is

not uncommon to see dull bits with one or more broken cutters in the center. This can
happen during drill-out of casing equipment but may also be due to the high cutter forces.
This type of breakage is not typically thought to be due to impact. In higher ROP
applications the drilling slope on the first few cutters is very steep and may rub the actual
cutter substrate or cutter pocket if too little back rake is used. Since the drilling slope
decreases from the center of the bit towards gage, more aggressive back rake angles can
be used on the nose and shoulder without creating a rubbing problem. Cutters toward the
gage of the bit can utilize higher back rakes to improve impact and wear resistance.
Since the engagement area per cutter decreases towards the outside of the bit, increasing
the back rake in this area does not have as significant affect on efficiency. Therefore, the
standard back rake scheme for FM3000 products is higher back-rakes in the center,
decreasing across the nose and shoulder for efficiency, and increasing again towards gage
for durability.
Side rake angles less than 20 degrees have NOT been found to have a profound effect on
cutting efficiency or impact resistance. On spiral bladed bits, side rake can decrease the
“stepping” effect of the cutters along the blade. Increasing side rake on highly spiraled
cutter layouts will create a smoother transition from the face of one cutter to the face of
the next cutter. This will improve the amount of cutter support on highly spiraled designs
as discussed in the blade layout section.
The example below shows the standard distribution of back rakes for FM3000. This is
the distribution a design should have before force balancing the bit. During force
balancing, the back rakes of the cone cutters may be altered. Only gage cutters should
have 30o back rake. The standard side rake for FM3000 bits is 5 degrees from center to
gage but should be adjusted according to degree of spiral.

Two Layer Cutting Structures

Two Layer Theory
Typical cutting structure layouts are comprised of cutters distributed on blades located
along the same cutting profile (Fig. 1B). Two layer cutting structures are layouts that
utilize under exposed layers of cutters on blades within the cutting structure. (Fig 1A &
1C).
The secondary layer of the cutting structure is underexposed to a determined depth to

ensure that all 2nd layer cutters have the same critical depth of cut. The critical depth of
cut is determined by the ROP & RPM that the second layers start to cut for the desired
application.
It is also important to understand that the cutter wear of the first profile layer has a role in
the critical depth of cut during drilling. It is recommended that the underexposure of the
second layer be close to the cutter wear depth of the first profile layer for when the
second layer is desired to engage. The desired underexposure of the second layer
corresponds to a given drilling distance and wear depth of the first profile layer of the
drilling application. An example of this process can be seen below in the sample
application utilizing a two layer cutting structure. (Fig. 2).

Another way to utilize the two layer method is to change RPMs during drilling to
selectively engage or disengage the 2nd layer from contact during the interval. Changing
the RPMs during the drilling application to achieve a desired depth of cut will enable the
use of the secondary layer of blades.
Two Layer Applications

Understanding an area’s application is crucial in determining if a Two Layer cutting
structure is beneficial for the given drilling interval. One type of application where a Two
Layer cutting structure might increase the drilling efficiency is an interval with two
distinct formations requiring one bit (Fig. 3). Formation “A” is an interval that would
typically require a 4 blade bit and Formation “B” is an interval that requires an 8 blade
bit. An 8-blade Two Layer Cutting structure could lead to increased drilling efficiency in
this type of application. In this example, the underexposure of the second profile layer
would be set to engage at the start of Formation “B”.

Another application that might benefit from a Two Layer cutting structure would be a
formation that is lower compressive strength but higher in abrasion. In the example
below, “Distance 1” is the interval length that a 4 blade bit could drill efficiently under a
given ROP and RPM. At the end of this distance the cutters would be worn to a value of
0.1”. The start of “Distance 2” the remaining 4 blades would engage to drill the
remaining interval.
Two Layer Benefits

Two Layer cutting structures allow an increase in drilling efficiency for intervals where
lithology and wear amounts can be predicted. Dull and data analysis for the application is
vital to determining if a Two Layer cutting structure should be pursued. An offset well
parameter analysis and SPARTA rock strength model would be beneficial in determining
the appropriate design features for a Two Layer cutting structure.
Two layer cutting structures can also benefit applications where RPMs can be adjusted to
engage secondary layers for a given application and formation. For example, an
application where a shale interval requires 4 blades and a sandstone requires 8 blades
could utilize the Two layer method for engagement in each interval. The cutting structure
would be designed to engage 4 blades during a higher RPM shale interval and utilize
lower RPMs to achieve the critical depth of cut required to engage all 8 blades during the

sandstone interval. Once exiting the sandstone interval, RPMs could then be increased to
engage only 4 blades in the shale interval.
Documentation and Sources

Please refer to “Two_Layer_Technical_Presentation” and
“User_Manual_Design_TwoLayerCutting” presentations for further explanation and
instructions on designing Two Layer Cutting Structures.

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Fixed Cutter Bit Design Manual

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

The following chart gives a general

Bit Cutting Efficiency

60 RPM 210 60 60 210 60

Track Set and Trac-Loc

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

This restoration force has been confirmed

restoration forces for a 13mm TRAC-LOCTM

cutter in several rock types. Note that the scale

This simple study reinforces what we have seen

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

Examples on the following pages show typical track setting characteristics.

Date: June 1,2015 Initial By Assignee: ________

One Start Redundancy (TRAC-LOCTM): Cutter positions were determined on B1.

Date: June 1,2015 Initial By Assignee: ________

Three Start Redundancy (Opposing): Cutter positions determined on blades B1,

Three Start Redundancy (Trailing): Cutter positions determined on blades B1, B3

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

Some examples are:

Date: June 1,2015 Initial By Assignee: ________

Back Rake and Side Rake Angles

Date: June 1,2015 Initial By Assignee: ________

Cutter position and rake angles

Cutter position and absolute rake angles

Date: June 1,2015 Initial By Assignee: ________

Date: June 1,2015 Initial By Assignee: ________

Two Layer Cutting Structures

The secondary layer of the cutting structure is underexposed to a determined depth to

Date: June 1,2015 Initial By Assignee: ________

Two Layer Applications

Date: June 1,2015 Initial By Assignee: ________

Two Layer Benefits

Date: June 1,2015 Initial By Assignee: ________

Documentation and Sources

Date: June 1,2015 Initial By Assignee: ________

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