In an industry first, high-frequency measurements of in-situ cutter forces and bit dynamics have been captured across diverse applications. These data reveal unprecedented details of how cutter forces vary with formation properties and drilling system dynamics, offering new insights to optimize bit design and drilling performance.

In this paper, we present data from a diamond cutting element which has been instrumented to measure cutting force, three-axis acceleration, bit rotation speed, and the earth's magnetic vector at high frequency. These cutters are integrated into PDC drill bits of various sizes and blade counts for different drilling applications. After drilling, the data is combined with rig-floor recording and downhole measurements to analyze formation properties and cutter–rock interactions in time and space. Borehole imaging is used to visualize formation features and link them to drilling performance, while the influence of bit and the bottomhole assembly (BHA) design, operating parameters, and drilling dynamics on cutter-rock interaction is systematically evaluated.

PDC bits equipped with the instrumented cutting elements have drilled multiple well sections in different locations. Borehole imaging showed various formation characteristics affecting drill bit performance, including hard stringers, interbeds, vugs, hard inclusions, and cracks, etc. These formation characteristics correlate with drill bit dynamics such as lateral vibration and stick slip. Both formation characteristics and drilling dynamics affect drill bit rate of penetration (ROP) and bit longevity. Cutter instrumentation provides highly granular formation data which can be used to evaluate formation details to evaluate drilling risks such as borehole instability and loss circulation. Non smooth cutter-rock interaction was observed when drilling with a mud motor having a bent housing. Cutting force shows a unique pattern when severe stick/slip happens, corresponding to different phases of the stick slip cycles. It explains the drilling efficiency loss due to torsional and axial dynamics coupling. Other interesting events observed include drillstring microhang-ups and bit whirling during drill off period.

The instrumented cutting element technology recorded detailed in-situ cutter-rock interactions, providing data to enhance drilling system design and performance. Future studies will use these measurements to analyze formation properties such as strength, anisotropy, inhomogeneity, orientation, fractures, and their impact on drilling operation, efficiency and dysfunctions.