The Influence of Polishment on PDC Cutter

Polishing is the process of creating a smooth and shiny surface by rubbing it or by applying a chemical treatment, leaving a clean surface with a significant specular reflection.

When an unpolished surface is magnified thousands of times, it usually looks like a succession of mountains and valleys. By repeated abrasion, those "mountains" are worn down until they are flat or just small "hills." The process of polishing with abrasives starts with coarse grain size and gradually proceeds to the finer ones to efficiently flatten the surface imperfections and obtain optimal results.

Regarding the polishing for PDC cutters, the procedure of polishing consists of grinding the front face of the cutter. This procedure gives a mirror-like appearance to the cutter's face.

Smith performed tests with standard and polished cutters on several types of rocks (shales, limestones, and sandstones), using a single-point cutting machine. The tests were performed in atmospheric conditions and under confinement. For most of the rocks tested, the use of polished cutters showed improved efficiency in comparison with standard cutters. From laboratory experiments and field data, he concluded that polished PDC cutters mobilize a significantly reduced coefficient of friction compared to non-polished cutters. 

Baker Hughes has developed StaySharp premium polished cutters. The cutting teeth are sintered with a mesh structure so that the composite sheet and the matrix are more closely combined. And the thickness of the diamond layer and cutting stability is increased. The high-quality polishing technology of the cutting teeth is used to greatly improve the smoothness of the surface of the cutting teeth, which is beneficial for the cutting teeth to enter the formation and reduce the friction with the formation and cuttings, force to avoid bit mud packs. A polished PDC cutter has better cooling and stays sharper longer compared with a non-polished PDC cutter. 

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