What are the best practices for testing a new drill bit design?

If the new design is a radical new one meaning something completely different to a three-cone bit or a PDC the best way is to take blocks of rocks and perform initial tests including simulations with dedicated software before going to the field. Instead if the new design is just an evolution of an existing one that was developed based on actual results, experience and field data, then a field trial with sections drilled using a drill-in test to evaluate the actual performance is a must. Other people just go and try!

Testing a new drill bit design involves thorough laboratory and field trials, collecting performance data, considering rock properties, analyzing dull bit patterns, utilizing simulation models, fostering collaboration, and conducting cost-benefit and environmental assessments. Clear communication and a feedback loop between stakeholders are crucial for refining the design based on real-world performance.

Drilling involves rock -bit interation , resulting in ROP and dull condition of the bit. This is a function (f (x)) of lot of factors other than actual drill bit design itself. 1) Initial testing is in design software by simulating external factors and calculating the imbalance forces, toques generated by each cutter and as whole bit. If these are within limits the design proceeds. 2) The lab test results of different cutters giving the information of impact and abrasive resistance. 3) CFD analysis for Nozzle placements 4) Above all are we can say inhouse tests. Actual bit run with proper pre run plan will be the practical test which will help to test the bit and record lessons learned and future improvements to be made.

Laboratory Testing: Conduct laboratory testing in a controlled environment to assess basic functionality, wear resistance, and other performance characteristics. This may involve using drilling simulators or testing equipment under controlled conditions.

Regarding Drill Bits, I consider that everything has not been discovered, the patents have expired and many companies have been formed and are going to compete in the current market, the current companies have Testing laboratories in their facilities, stress tests and their products have been tested In many fields, better cutters, better protection material have been added, but there will always be other tests to improve the results. From experience, I affirm that a well to be drilled 30 feet from the other can present totally different lithologies (depending on the area), so laboratory and field analyzes will always be necessary when developing new drill bits or competitive ones with existing ones.

Field Testing: Perform field tests in actual drilling conditions. This could involve collaborating with drilling operators to use the new drill bit in real-world scenarios. Field testing provides valuable insights into the drill bit's performance under diverse conditions

Data Collection and Analysis: Collect comprehensive data during testing, including penetration rates, wear patterns, and any failures. Analyze this data thoroughly to evaluate the drill bit's overall performance and identify areas for improvement.

Testing a new drill bit design involves thorough laboratory and field trials, collecting performance data, considering rock properties, analyzing dull bit patterns, utilizing simulation models, fostering collaboration, and conducting cost-benefit and environmental assessments.

Most of the time, finding the right bit for a given application is an initiative with significant opportunities for continuos improvement. Having an efficient control of shocks and vibrations is key to pursuit performance beyond the technical limit. The adoption of technology for an automatic control of the bit depth of cut (DOC) as part of the BHA for example had been key to enhanced ROP and extended bit life in many complex projects ✔️