Drill Bit Design Features that Initiate and Reduce High Frequency Torsional Oscillations
Abstract This paper reports the development of and the results of high frequency torsional oscillation (HFTO) tests performed on full-sized PDC drill bits and single cutters in a drilling laboratory. The research team used a pressurized laboratory drilling rig to test different drill bit designs in new and worn conditions. These tests were performed in different rock types, at different revolution per minute (RPM), weight on bit (WOB) and depth of cut (DOC) values. High frequency drill stem torque (5120 Hz) and in-bit tangential acceleration (1400 Hz) data were recorded, along with all other drilling parameters. Spectrograms of torque data were plotted to identify frequency changes in time. The torque data was filtered to remove the low frequency behavior and focus on the HFTO behavior. The high frequency torque signal correlates well with in-bit tangential accelerations. Root mean square (RMS) values of this filtered torque signal were calculated and plotted vs average WOB, depth of cut, and torque values. Sharp and worn bit geometry, were dull graded on a per cutter basis and were input to a 3D drilling modeling software and correlated with test data in order to determine the DOC at which wear flats or cutting faces engage the rock and cause changes in HFTO behavior. The main results from this research are 1) a lab test and data analysis were developed that can measure a drill bit's propensity to initiate HFTO vibrations in the BHA, 2) HFTO RMS high-pass filtered torque values generally increase with DOC, 3) bits in the new state show more HFTO behavior if cutter design is more aggressive, and 4) wear flat engagement causes high HFTO behavior.