Talking TeChniCally

Selecting the right core bit

Driller checking outside diameter of an Excore core drilling bit.

Crucial operation

Selection criteria
Atlas Copco is an experienced ISO certified supplier offering a full range of equipment for all underground and surface exploration drilling applications. This includes rigs and a full range of high technology and high quality products, including (ITH) In-The-Hole tools and core drilling bits which are designed to maximize customer profitability. All products are designed to minimize downtime and maximize productivity. Atlas Copco core bits range from a Series 1 bit for the softest application to Series 10 bit for the hardest application. The numbers correspond to the different rock groups by hardness, and as a general rule, the harder the formation, the higher the series number required. However, other factors bear on the choice of bit, most important of which are the characteristics of the rock

Drilling with a core bit is introduced at an advanced stage of the exploration operation, by which time substantial resources have already been spent. The quality and continuity of the captured core is crucial in the assessment of a potential mine, making the core bit a key component of a core drilling rig. Core bit selection is based on the size and depth of hole and the hardness of the rock, taking into account the rig capacity and condition, the flushing medium, and the skills of the driller. To ensure the correct core bit, the drilling contractor needs a reliable bit supplier with the right hands-on experience to advise the best solution for every condition. Atlas Copco manufactures the entire range of core drilling tools, and will recommend and supply the type and designation most suited to the application.

formation, its hardness, grain size, abrasiveness, competence, and whether the strata is fractured or changing. The lift and feed force of the drilling rig, together with its rotation speed and chuck and rod holding capacity are other factors. Some rigs have better controls than others, and this must be taken into account. Smooth control of feed force, and accurate control of water flushing and rotation are key factors, along with the drillers technique. A variety of core bit types is available based on the diamond cutting elements used in their construction. The impregnated diamond core bit is most popular, followed by surface set diamond bits, tungsten carbide and polycrystalline diamond composite bits. Impregnated diamond bits should generally be used with a peripheral speed of 2-5 m/sec, depending on rock condition and machine capacity.
exploration drilling

36

Talking TeChniCally

impregnated diamond core bits

In most geological formations, impregnated bits are more economical to use than surface set bits as they provide additional benefits: greater resistance to wear in most formations, (particularly in hard and fractured formations), less sensitive to abuse, rough handling and improper use. Synthetic diamonds are used in the manufacture of Atlas Copco impregnated bits, with some bits using natural diamonds as gauge stones. The consistency of quality, shape, granular size, and strength make synthetic diamonds superior to natural stones. Impregnated diamond drill bits are designed to perform as grinders. Diamonds are embedded in an infiltrated or sintered matrix, which erodes away at the same rate as the diamonds become worn and rounded. Thus new sharp diamonds are exposed to continue cutting through the rock. The combination of diamonds and matrix determine the bit performance, and the simultaneous erosion of the matrix and the diamonds makes the bit self-sharpening. The ideal combination of optimal penetration rate and wear resistance is matched to achieve the ultimate in drilling economy. The diamonds are carefully selected by quality and size for the application. Through advanced manufacturing technology an extensive range of drilling requirements can be satisfied. Continuous control at each step in the manufacturing process ensures that all bits are of identical high quality. This consistent high quality means more drill metres per bit. Impregnated diamond bits are the bit most commonly used in exploration drilling, and are particularly recommended in the hard to extremely hard formations of rock groups 6-10. Productivity has constantly improved due to intensive research and development, which has introduced new generations of synthetic diamonds, metal alloy and improved production processes. As a result, impregnated bits can be used in almost all applications except clay, chalk and other unconsolidated formations. The impregnated bit matrix is available in a Series 1 through to Series 10
exploration drilling

according to rock hardness. Extended channel f lushing (ECF), channel flushing (CF), and face discharge (FD) waterways can be selected, along with Torpedo V and JET crown profiles for competent formations. Atlas Copco manufactures core bits in 10, 13 and 16 mm crown heights. In terms of drilling parameters, weight on bit and rate of penetration have to be taken into account, as do fluid volume, and rotation speed. The revolution per rate of penetration is normally in the range of 150-250 rev/in (RPI) or 60-100 rev/cm (RPC).

Extended Channel Flushing

Surface set diamond bits

Surface set diamond bits can be used to drill in soft to medium hard sedimentary formations, but in hard rock impregnated diamond bits are normally more cost effective. Surface set bits are designed to utilize specific diamond size and quality according to the application, they are available in step and semi-round crown profiles, with a choice of CF waterways for consolidated rock or FD waterways for use with triple tube core barrels to avoid core washing out in soft formations. Step profile is normally used for standard and thick kerf wire line bits and is suitable in almost all kinds of formations, where they offer good penetration rate and stability. Semiround profile is used for conventional and thin kerf wire line bits. Atlas Copco surface set bits are manufactured to the highest standards in the industry, for the ultimate in drilling performance. They employ a hard type of matrix for all formations, and use selected and processed diamonds with a highly polished surface. These stones have a high impact resistance, and have been developed from many years of practical field experience. If the formation is soft a larger stone is utilized which results in fewer sones per carat. Harder formations require smaller stones. The setting patterns are important to the long service life, high penetration rate, and adaptability to changing formations that characterize this type of bit. Atlas Copco uses best quality processed N, S and P diamonds suitable for hard to soft formations. Most common

Torpedo "V"

Jet

Face Discharge

Diamond Surface Set (SS)

Poly Crystalline Diamond Composite (PDC)

Tungsten Carbide Insert (TCI)

37

Talking TeChniCally

in the matrix and are recommended for harder sedimentary formations.

Reaming shells
A reaming shell should always be used in a coring system. It is a core barrel component, which joins the bit to the core barrel outer tube. The outside surface of the reaming shell is set with diamonds to a specified diameter, normally larger than the bit diameter. This provides a constant hole diameter independent of bit wear, and accommodates changing the bit without getting stuck in the hole. They also serve as a stabilizer, reducing vibration and prolonging the life of the bit. Reaming shells are designed with a tapered leading edge to ream the hole. Well designed waterways, reinforced with PDC pins, facilitate effective flushing and contribute to long service life and good drilling economy for both reaming shells and drill bits. For some core barrel systems there are optional reaming shells, longer than the standard, designed with two or three diamond set gauge rings. The longer reaming shells have to be used together with an optional extension sleeve for the inner tube. Double and triple ring reaming shells are used to improve hole deviation problems. Impregnated reaming shells full hole profile are also available, when added stability is required. Casing and rod shoes are manufactured to handle a broad range of conditions, from unconsolidated overburden to broken, abrasive formations. Impregnated standard and heavy duty casing shoes as well as surface set casing shoes are available, rod shoes are available only in an impregnated design.

Atlas Copco representative discussing diamond tool selection with driller.

quality is S, which is a natural, selected-, processed diamond, suitable for almost all applications. The size of diamonds, or stones per carat, is important because the harder the rock, the smaller the stones.

recommended in medium to mediumhard sedimentary formations. All TC bits can be used in clean-out operations, such as for the removal of steel fragments from a drill hole.

Tungsten carbide (TC) bits

TC core bits are used for drilling in non-consolidated formations and in overburden, and for cleaning drill holes. They are used for soil investigations and geotechnical drilling, and can also be used for mineral exploration for coring in softer rock formations. Atlas Copco manufactures two different types of bits with octagonal tungsten carbide inserts. Another type of tungsten carbide bit with more cutting edges than standard TC bits is Corborit,
38

Poly-crystalline diamond composite bits (PDC)

PDC bits are an alternative to TC bits and surface set diamond bits, when drilling in non-consolidated and medium hard rock formations such as salt, potash, limestone, and clay stone with no crystalline or chert or similar intrusions. Atlas Copco offers two types of PDC bits known as Diapax and Tripax. Diapax bits have brazed round PDC inserts, while Tripax bits have brazed cubic or triangular PDC inserts embedded

Summary
To maximize drilling efficiency, choose the right drill bit and utilize sound drilling practices. There is no substitute for testing the system at site, because all sites are different, all formations are different, and all clients requirements are different.

gerry Black

exploration drilling

Talking TeChniCally

exploration drilling

39