Roller Cone Bit Geometry

The shape and profile of a bit depends partly on hole-size constraints and partly on the type of cutting action desired.
The one unalterable constraint on overall bit design is the diameter of the hole to be drilled. Bit components must be
of the proper sizes and proportions to fit within this limited space. Hole size determines which design variations are
possible, and sometimes makes it necessary to enhance one design element at the expense of another. The larger
the hole size, the more flexible designers can be in developing a well-balanced, optimum-performing bit.

Cone Profile Angle

Because it is not possible to fit three true rolling cones into the confined diameter of the borehole, designers must
align them at an angle. Cone profile angle is a design concession to hole-size restrictions. There are normally three
types of cone profile angles on tri-cone bits:
Inner cone profile angle, in which the front part of the cone is trying to roll around an axis which is normally past the

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center of the bit;
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Intermediate cone profile angle, in which the intermediate section of the cone rotates around an axis that is generally
in the area just outside the bit diameter;
Outer cone angle, or gauge, in which the apex of the outer cone is trying to revolve around a point considerably
outside the bit's outside diameter.

The result of these cone angles is that the gauge (outer) rows produce a trailing/skidding action, while the inner rows
are in approximately a true roll and the intermediate cone angle is a major area of bit wear.

Journal Angle and Offset

The geometric design features that determine cutting action are the journal angle (where the journal is the bearing
portion of the bit leg, as shown in Figure 1), and the offset.

Journal Angle
The journal angle, by definition, is the angle formed by the intersection of a line perpendicular to the axis (or center
line) of the journal and the center line of the bit.

Soft formation bits ( Figure 2) have smaller journal angles than hard formation bits ( Figure 3). For example, a soft or
medium formation bit may have a journal angle of 32.5, while a medium hard or hard formation bit may have a
journal angle of 36. Some specialty bits have a 39 journal angle.

Journal angle determines the following design parameters:

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Out-thrust load: By design, all three-cone bits load in an outboard or out-thrust manner.
Journal diameter: The journal diameter must be large enough to provide adequate strength so that the journal will not
fail under high bit loads or rough drilling conditions such as bit bouncing. Note that the journal and leg of the bit are moment arm-type
structures, which can deflect under load and load cycles. These cycles can produce fatigue and breakage, resulting in the loss of the
journal/cone assembly in the hole.
Inner cone angles: As shown in Figure 2 and Figure 3 , soft formation bit types with low journal angles (32.5) have
greater cone profile angles and a higher crowned bottom hole profile than hard formation, higher journal angle (36) bits. Higher journal angle
bits have a flat bottom-hole profile.
Roller bearing diameters and lengths: Journal angle affects the size and length of various roller bearing type bit
designs.
Shape of gauge teeth and degree of gauge tooth cutting action: The journal angle, together with the amount of
offset in angle bit design, affects the gauge tooth shape and the degree of cutting action it provides.

Offset
Offset is the horizontal distance between the center line of the bit and a vertical plane through the center-line of the
journal. Figure 4 shows this offset as a positive displacement in the direction of rotation (some bit

companies measure offset in inches, while others measure it in degrees. Typical bit offsets range from 0
to 5).

In general, the greater the offset distance on a bit, the higher the degree of gouging/scraping cutting action it has.
Soft formation bits generally have offsets that are considerably larger than those of hard formation bits ( Figure 5).

All bits are designed with some amount of positive offset. If a bit were to have a negative offset, it would produce a
skidding and trailing action in the cutting structure, resulting in reduced penetration rates, abnormal wear of the
cutting structure and premature failure.
The following bit parameters depend on offset:
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In-thrust load: The greater a bit's offset, the more the gauge contact between the cone and the borehole wall is
reduced and, therefore, the greater the in-thrust loading (remember that by design geometry, all three-cone bits load in an out-thrust
manner).
Shape of the gauge teeth: The greater a bit's offset, the more aggressive (i.e., gouging/scraping) is its cutting action.
To facilitate this cutting action in soft formation bits, the cutting structures are made as long and thin as possible. Hard formation bits with less
offset use shorter, broader teeth or inserts to increase resistance to breakage and wear;
Degree of reaming action and gauge tooth wear: The greater the offset, the less the amount of contact between the
gauge face of the cone and the borehole wall-bits with zero offset would have maximum hole contact.

This is important to understand because as offset increases, the tooth round decreases and tooth space increases. It
is therefore necessary, when gauging a soft formation bit, to position a gauge tooth at the gauge point. Otherwise, a
gauge ring can be passed over the cutting structure, creating the illusion that a new bit is out of gauge.
The amount of contact that the cutter has with the borehole wall will, of course, influence the degree of wear and the
life of the gauge tooth.
Cutting Elements
The two basic categories of rolling cutter bits are defined by their cutting elements. A bit may either have milled steel
teeth ortungsten carbide inserts.

Milled Steel Tooth Cutters

Milled steel tooth cutters are an integral part of the bit cone. Their design parameters include shape, spacing and
positioning on the cone, and hardfacing patterns.

Shape, Spacing and Positioning

Soft formation bits have long, relatively thin teeth that are spaced widely apart on the cone ( Figure 1 ).

This configuration promotes a gouging/scraping action that results in high penetration rates with minimal weight on
bit. Unfortunately, these long teeth are especially susceptible to breakage in harder rock. Hard formation bits
therefore have shorter, smaller, more closely spaced teeth designed to drill at higher bit weights ( Figure 2 ).

Figure 3illustrates the following design parameters relating to shape and positioning of the teeth:

Teeth are positioned on the cone in rows, with the inner rows on each cone meshing with one another.
This tooth arrangement provides the optimum design space for a given hole size, promotes self-cleaning of the teeth as the bit
turns, and provides maximum hole coverage;
Indentations or interruptions, also called skip spacing, may be placed on the heel (outer) row of teeth. These indentations, which
are smaller than the teeth themselves, help prevent cuttings from wedging between teeth. They also help in reducing the tracking at the
formation face.

Hard-facing
Hard-facingthe selective application of ground particles of tungsten carbide in a welded matrix has become an
important component in tooth design. Application of hard-facing material can reduce tooth wear, thereby increasing
both the average penetration rate and overall footage for the bit run. Manufactures can selectively apply hard-facing
to inner and gauge teeth in a variety of patterns that not only protect the teeth, but promote self sharpening wear.
Figure 4 shows some typical hard-facing patterns.

Tungsten Carbide Inserts

Tungsten-carbide insert (TCIs) are not part of the cone material. Rather, they are separate elements, pressed into
specially machined holes in the cone. TCIs can be placed either as gauge inserts (along the outside of the cone) or
inner row inserts.

Insert Shape
Shape is an important criterion in insert design. The same general rule of thumb applies for inserts as for milled teeth:
long-extension, chisel-shaped inserts for soft formations, and short-extension, rounded "button" inserts for hard
formations. Beyond this basic guideline, inserts can have a variety of shapes, several of which are described below.
Gauge Chisel: This type of insert ( Figure 5) has a flat surface on gauge, giving it considerable contact area with the
borehole compared to other gauge shapes.
It normally has a short extension, and is susceptible to heat generation and cracking. The standard chisel on gauge
design can be of various lengths, and has a radial surface in contact with the hole wall.

Inclined Gauge Chisel: This is a special-angle insert designed to actually drill in gauge rather than using a
conventional wiping/reaming action ( Figure 6).

Conical: This insert type is symmetrical (parabolic) and shaped much like a bullet. It varies in length and extension
( Figure 7).

Semi-round top: Hemispherical in shape, this insert type is also used for diamond-enhanced insert designs ( Figure

8).

Wedge crest chisel: This is similar to the gauge chisel except that the crest, rather than being straight like a tooth, is
flared out. The insert has a flat surface contacting the hole wall
Chisel crest inserts: These are shaped much like the teeth on milled tooth bits. The more aggressive, speedresponsive, soft formation insert bits utilize extended chisel crest designs with long protrusion or extension from the
cone shell. These inserts normally have sharp crests and low included angles.
Medium and short chisel shapes have relatively large crest radii and included angles, resulting in greater crosssectional areas than are found on long shapes. This makes them stronger and more capable of drilling higherstrength formations without chipping and breaking.

Materials
The various grades of tungsten carbide may be categorized in terms of their abrasion and impact resistance:

Abrasion Resistance: The G-Ratio measures cutter wear in turning down a standard granite cylinder. The ratio is calculated by
dividing the volume of granite removed by the volume of diamond removed during the test.
Impact Resistance: The cutter impact test provides a comparative standard of impact toughness. The energy required to reach
pre- defined damage conditions serves as the measurement of relative impact toughness.

Bearings
Bearings are what separate roller cone bits from fixed cutter bits. They enable the cones to turn on their axes so that
the teeth or inserts can perform their cutting action. Bearing selection can have a significant influence on bit life.

Bearing Types
Roller cone bits are equipped with either roller bearings (open or sealed) or journal bearings. Within these
categories are three basic, commonly-used bearing structures: roller-ball-friction, roller-ball-roller and frictionball-friction.

Roller-Ball-Friction Assembly
A standard roller-ball-friction assembly consists of roller bearings in the main bearing, ball bearings (cone retention
system) and a friction bearing in the nose (front). This design is used in all open (non-seal) bearing bits and also in
some sealed roller bearing bits ( Figure 1. Courtesy of Ural BMT (http://uralbmt.com)).

Roller-Ball-Roller Assembly
A roller-ball-roller assembly consists of roller bearings in the main bearing, ball bearings in the middle and roller
bearings in the nose area (replacing the friction bearing). This bearing design is used in 12" and larger bits, and
would be found in both open bearing (non-seal) bits and sealed roller bearing bits ( Figure 2: Roller bearing, TCI bit.
Courtesy of Varel International. All rights reserved)

Friction-Ball-Friction Assembly
A friction-ball-friction assembly, consists of a friction bearing in the main bearing area, ball bearings in the middle and
a friction bearing in the nose. This design is used in all journal bearing bits ( Figure 3 : Journal bearing, steel-tooth bit.

Courtesy of Varel International. All rights reserved).

Friction-ball-friction type bits have four basic designs:

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Friction pad, utilizing a welded-in bearing material in the main bearing portion of the cone;
Segmented sleeve, which uses a two-piece bearing sleeve that fits between the cased surface in the main bearing
portion of the cone and the welded material on the load side of the leg journal. This sleeve serves as a slip bearing that acts as a speed
reducer, and eliminates the need for welding inside the cone bore;
Solid journal, which utilizes a welded pad on the load side of the leg journal, but has a solid 360 precision groundbearing surface on the leg journal. This gives maximum cone leg contact and provides balance and stability;
Spinodal one-piece split sleeve, which consists of a solid 3600 precision ground bearing with a cased bearing
surface in the main bearing of the cone, a welded pad on the load side of the leg journal and a floating single split sleeve bearing which acts
as a slip bearing or speed reducer.

Bearing Selection
The modes of failure for roller bearing and journal bearing bits differ significantly. To select a bit type for a specific
application, we need to understand these differences.
The mode of failure for roller bearing bits is spalling.The rolling bearings deflect a case-hardened roller bearing race
on the leg journal. At some combination of load and number of cycles, the roller race reaches its endurance limit and
fatigue failure of the case occurs, causing the race to break up or "spall." As space is created through this spalling
action, the roller bearings stack up on each other, creating a very high lockup torque. Banging of the rotary table,
together with "jumping" and torquing-up of the drill string, are surface indicators of this lockup torque. These
indications usually occur before the cone is lost from the bit, thus providing an early warning of bearing failure.
Journal bearing bits have friction bearing surfaces or sleeve bearing designs that can carry higher loads, but that also
require a sealed lubricant environment. Bearing failure occurs when fluid leaks into the seals as a result of wear. The
small torque increases that indicate failure may be very hard to detect; even when detected, they are frequently
attributed to the formation rather than to seal/bearing failure. The time interval during which complete failure occurs is
very short in comparison to roller bearing bits, thereby increasing the potential for cone loss.
Because roller bearing failure is much easier to recognize than journal bearing failure, a sealed roller bearing bit may
be preferable to a journal bearing bit when drilling at high rotary speeds (i.e., 250-300 rpm), or when using a
downhole mud motor or turbine. Such a practice may lessen the likelihood of losing a cone in the hole.
In general, due to point loading in the roller bearings, roller bearing bits cannot take as much weight as journal
bearing bits.