Everything You Need To Know About PDC Cutter

PDC (Polycrystalline Diamond Compact) cutters are an essential tool in the drilling industry, altering how we extract resources from the ground. PDC cutters, with their higher hardness, wear resistance, and thermal conductivity, have become the preferred choice for drilling firms aiming to boost efficiency and save costs. In this post, you can learn some important information about diamond cutters and how they can bring value.

The structure of PDC cutters

Understanding the structure of PDC inserts is crucial for grasping their functionality and advantages. Here’s an overview of the key components:

1. Diamond Layer

Material: PDC cutters are made from polycrystalline diamond-synthetic Diamond, which consists of tiny diamond crystals bonded together under high pressure and temperature.

Function: This layer provides exceptional hardness and wear resistance, enabling the cutter to effectively penetrate hard rock formations.

2. Cemented Carbide Substrate

Material: The diamond layer is typically bonded to a substrate made of cemented carbide, which is known for its toughness.

Function: This substrate supports the diamond layer and absorbs the impact forces during drilling, enhancing the durability of the cutter.

3. Cutting Edge

Design: The cutting edge is shaped to optimize cutting efficiency and can vary in geometry depending on the application.

Function: This edge is where the actual drilling occurs, allowing for precise penetration into various geological formations.

4. Cooling Channels (Optional)

Design: Some PDC cutters may feature integrated cooling channels.

Function: These channels help dissipate heat generated during drilling, improving performance and extending tool life.

The shape of PDC cutters

The standard PDC cutter cylinder is not the only shape for cutters on the market today. Shaped PDC cutters are evolving in every aspect of the drilling arena. The basically shape now zzbetter offers:

1. PDC flat cutter

2. PDC ridged cutters

3. PDC half cutter

4. PDC Spherical (dome) button

5. PDC Parabolic button

6. PDC Conical button

7. Irregular PDC cutters and customized

ZZbetter has a wide variety of shapes PDC cutters with exceptional performance for down-hole drilling. Whether you are looking for increased ROP, optimized cooling, better depth of cut and formation engagement, or better secondary cutting elements, you can always find solutions at ZZBETTER. 

The size of PDC flat cutters

1. PDC cutters of 8 mm diameter have been used on products designed for harder formations. In fact, the first PDC manufactured was this size. The sizes are 0804 PDC cutters, 0808 PDC cutters, and 0810 PDC cutters.

2.Diamond drilling bits of 13 mm cutters are the industry standard size, like PDC 1304, pdc 1308, pdc 1313. They are most suitable for cutting medium to medium-hard formations as well as abrasive rock. 

3. Generally associated with fast drilling, PDC bits 19 mm are most suitable for drilling soft to medium formations when mounted in high-bladed style bits. There are PDC 1908, PDC 1913, PDC 1916, PDC 1919. Because larger cutters produce large cuttings in the right application, they are extremely useful when drilling with oil-based mud or water-based mud in a hydratable formation.

The application of PDC cutters

PDC cutters are a versatile and valuable tool that can bring significant benefits to a wide range of applications

1. Oil and Gas Drilling 

One of the most common applications of PCD cutters is in oil and gas drilling for PDC drill bits. These diamond cutters are used in both fixed cutter and roller cone drill bits to efficiently drill through hard rock formations. PDC cutters are known for their ability to maintain their sharpness and cutting efficiency even in high-temperature and high-pressure drilling environments. By using PDC cutters, drilling companies can increase their drilling speed, reduce downtime, and ultimately lower their overall drilling costs.

2. Mining 

PDC cutters are also widely used in the mining industry for drilling blast holes, exploration holes, and production holes. These cutters are capable of cutting through hard rock formations with ease, making them ideal for mining operations. By using PDC cutters, mining companies can increase their drilling efficiency, reduce wear and tear on their drilling equipment, and ultimately improve their overall productivity.

3. Construction 

In the construction industry, PDC cutters are used for various drilling applications, such as drilling foundation piles, tunnels, and water wells. These cutters are known for their durability and long lifespan, making them a cost-effective choice for construction projects. By using PDC cutters, construction companies can increase their drilling speed, reduce the need for frequent cutter replacements, and ultimately save time and money on their projects.

4. Geothermal Drilling 

PDC cutters are also commonly used in geothermal drilling, where high temperatures and abrasive formations can pose challenges for traditional drilling tools. PDC cutters are able to withstand these harsh drilling conditions, making them an ideal choice for geothermal exploration and production. By using PDC cutters, geothermal companies can increase their drilling efficiency, reduce downtime, and ultimately improve their overall drilling success rate.

4. Road milling

Road milling, also known as asphalt milling or pavement recycling, involves removing the surface layer of a road to restore its condition or prepare for resurfacing. This process helps maintain road quality and extend the lifespan of the pavement. PDC cutters are essential tools in road milling, offering advantages in durability, precision, and efficiency. Their ability to handle tough materials while producing high-quality results makes them a preferred choice for road maintenance and rehabilitation. As the demand for efficient roadwork increases, the use of PDC cutters in this sector is growing, enhancing the overall effectiveness of milling operations.

5. Throttle Plate and nozzle

Throttling in the context of oil and gas valves refers to the process of controlling the flow of fluids through the valve by partially closing or adjusting the valve opening. The PDC valve is a nozzle-style, spring-loaded check valve that allows gases to flow in only one direction. The PDC valve offers users a variety of benefits; perhaps its most significant feature is its unique pulse-damping chamber

The PDC throttle plate has the characteristics of erosion resistance, corrosion resistance, and thermal shock resistance. The friction coefficient is low during the valve switch process, the coupling between the valve core and the valve seat is tighter, and the sealing performance is better.

Filter nozzles are critical components used in various filtration systems, including water treatment, oil and gas filtration, and industrial processes. They allow for the controlled passage of fluids while filtering out unwanted particles.

The advantages of PDC

Everything you need to know about the benefits of PDC cutters and how they can bring value to your drilling operations are as below.

1. Enhanced Durability and Longevity

One of the key benefits of PDC cutters is their exceptional durability and longevity. Made from synthetic diamond particles that are sintered together under high pressure and temperature, PDC cutters are incredibly hard and wear-resistant. This means they can withstand the harsh conditions of drilling operations, such as high temperatures, abrasive materials, and intense pressure, without losing their cutting edge. As a result, PDC cutters have a much longer lifespan compared to traditional cutting tools, reducing the need for frequent replacements and downtime.

2. Improved efficiency and productivity 

PDC cutters are known for their superior cutting performance, thanks to their ultra-hard diamond cutting surfaces. This allows them to maintain sharpness and precision even when drilling through tough rock formations or abrasive materials. As a result, PDC cutters can significantly increase drilling speed and efficiency, leading to faster completion of drilling projects and higher productivity. Additionally, the consistent and uniform cutting action of PDC cutters helps to reduce the risk of tool failure and costly downtime, ensuring smooth and uninterrupted drilling operations.

3. Cost-effectiveness 

While PDC cutters may have a higher upfront cost compared to traditional cutting tools, their long-term cost-effectiveness cannot be overlooked. The extended lifespan and superior performance of PDC cutters mean that you will save money in the long run by reducing the need for frequent replacements and maintenance. Additionally, the increased drilling efficiency and productivity offered by PDC cutters can help you complete projects faster and more efficiently, ultimately leading to cost savings and improved profitability.

4. Versatility and Adaptability 

PDC cutters are highly versatile and can be used in a wide range of drilling applications, including oil and gas exploration, mining, construction, and geothermal drilling. Their ability to adapt to different drilling conditions and rock formations makes them a valuable tool for various industries and projects. Whether you are drilling through soft sedimentary rock or hard granite, PDC cutters can provide the cutting power and precision needed to get the job done effectively.

ZZBETTER is excited to help you discover how our high-quality diamond solutions can enhance your work. Don't hesitate to reach out if you have questions or want to learn more about our PDC cutters.