TOUGH-DRILL™ PDC Bits
3 1/4" TO 18 1/2" (88.9 mm TO 469.9 mm) - In Matrix
8 1/2" TO 26" (215.9 mm TO 660.4mm) - In Steel
Varel’s TOUGH-DRILL™ PDC bits are designed for hard rock applications. Due to their improved stabilization characteristics, these bits address the ROP and durability challenges experienced when drilling hard and/or abrasive formations. TOUGH-DRILL bits combine advanced cutting structure layouts, high performance PDC cutters and superior hydraulic configurations to ensure ROP and durability improvements.
Through their comprehensive engineering and development process, TOUGH-DRILL bits reduce impact damage, improve cleaning and cutter cooling efficiencies. The high abrasion resistant cutters used in TOUGH-DRILL bits drastically minimize cutter wear. Our performance continues to validate our claims.
Hydraulics
As part of the product development process, TOUGH-DRILL bits go through elaborate computational fluid dynamics (CFD) evaluations. CFD eliminates re-grinding and re-circulation of drilled cuttings, a common occurrence when drilling hard and abrasive applications. In addition, possible stagnation zones are identified and eliminated. This sophisticated process improves cleaning efficiency, cutter cooling and ROP.
Advanced Cutting Structure
TOUGH-DRILL bits are developed using Varel’s proprietary design software called SPOT™. Using extensive single cutter tests and full scale bit tests in laboratory and field conditions, SPOT ensures cutting structure optimization for specific applications. SPOT models complete bit behavior in difference rock types during a simulated drilling process. This tool also evaluates cutter wear as a result of friction and heat transfer. Using appropriate rock geology and mechanical properties, SPOT also performs sensitivity analysis for various drilling parameters (WOB and RPM) to evaluate their effects on ROP, cutter wear, bit vibrations and footage drilled. Using SPOT improves the ROP and increases the footage drilled of each TOUGH-DRILL bit.
High Performance Cutters
Application-specific PDC cutters incorporating advanced carbide interface geometries (CIG) and materials are used in TOUGH-DRILL bits. The carbide interface geometries are modeled using finite element analysis (FEA) to minimize damaging residual stresses (axial, hoop and radial) improving impact resistance and extending cutter life, resulting in improved bit life. Diamond grades are then selected, analyzed and prepared to maximize abrasion resistance.
Powercutter™ Cutting Structure
Varel’s high-density “Powercutter” arrangement gives enhanced bit life when drilling a variety of rock types without sacrificing ROP. The new Powercutter cutting structure provides extra exposure and cutter density on the critical shoulder area of the bit. Bits can now achieve maximum rates of penetration through one rock formation and then continue to penetrate harder sand or limestone beds without excessive wear or damage e.g. interbedded formations.
Download TOUGH-DRILL brochure - English (PDF, 1.5MB)
Download TOUGH-DRILL brochure - Russian (PDF, 138KB)
