Since its introduction in early 2017, the ridge-shaped diamond cutting element (RDE) has been widely adopted to enhance rock-cutting efficiency in hard and very hard rock drilling. Its distinctive "ridge" enables a more effective cutting mechanism by simultaneously fracturing and shearing the rock. However, the cutting elements are facing increased challenges in transitional drilling – maintaining consistent cutting efficiency when dealing with a range of rock formations, from hard to medium-soft rocks. To address this and expand RDE's range of applications, we propose a new multi-ridge, three-dimensional cutter (3DC) design. This design is optimized to offer broader applicability and enhanced cutting efficiency across a wider variety of rock types.

Accelerated development methodology for the 3DC was adopted, incorporating virtual cutter–rock interaction simulations to investigate the cutting mechanism of the proposed multi-ridge design. The cutter shape was iteratively optimized through various physics-based digital rock-cutting models. Key parameters studied include ridge geometry, the number of ridges, and ridge contact angle offsets on a single cutter. A notable advantage of the multi-ridge design is its insensitivity to cutter orientation or rolling angle, which allows for more consistent performance across different downhole conditions. Additionally, bit drilling dynamics with this new 3DC is evaluated from an in-house developed proprietary drilling software. Based on the study, prototype cutters fabricated using premium laser-etched PDC elements were quickly deployed for field testing and validation.

Field tests were conducted to validate the performance of the new multi-ridge 3D cutter (3DC). Two deployment studies are presented. The field test results showed that this unique concept delivered performance improvement from a rate of penetration (ROP) point of view. The test conducted in Onshore U.S.A. with a curve and lateral well profile generated a 136 ft/h penetration rate (ROP), making it 20%higher than the closest comparable offset well ROP of 113 ft/hr. Another test in the onshore Middle East showed ROP improvement over the offset well average by 10% after the multi-ridge diamond element was installed at the baseline drill bit design with a conventional flat PDC cutter.