This paper presents a new methodology to predict the wear for three-cone bits under varying operating conditions. In this approach, six variables (weight on bit, rotary speed, pump rate, formation hardness, bit type, and torque) were studied over a range of values. A simulator was used to generate drilling data to eliminate arrors coherent to field measurements. The data generated was used to establish the relationship between complex patterns.

A three-layer artificial neural network was designed and trained with measured data. This method incorporates computational intelligence to define the relationship between the variables. Further, it can be used to estimate the rate of penetration and formation characteristics.

The new model was successful in predicting the condition of the bit. In this study, the value of 0.997 was obtained by the model as the correlation coefficient between the predicted and measured bearing wear and tooth wear values. The validity of the model was demonstrated with data from an existing field.

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