Polycrystalline diamond compact (PDC) bits often experience localized heating during impact rock breaking in complex formations, resulting in reduced service life and lower drilling efficiency. An optimized structural design of PDC cutters can significantly enhance bit performance, mitigate thermal concentration, and extend operational longevity. Inspired by previous work on PDC cutter surface topography, five saw-type tooth-shaped cutter designs—featuring one to five saw-type teeth were developed. To evaluate their rock-breaking effectiveness and identify the optimum design, the impact-induced rock fragmentation processes of these cutters were compared using the finite element method. Key indicators, including cutting force, mechanical specific energy (MSE), and cutter surface temperature, were analyzed to determine the superior tooth configuration. Among the five designs, the four-saw-tooth cutter induced the most pronounced stress concentration in the rock. Its optimized number of saw-type teeth ensured full participation of all teeth in rock cutting, enabling efficient rock removal and maximizing breakage performance. Compared with other designs, this cutter exhibited the smallest fluctuations and mean cutting force. The specific mechanical energy decreased initially and then increased with the number of saw-type teeth, reaching a minimum for the four saw-type tooth design. Moreover, it showed the lowest surface temperature and the mildest temperature variation, which helps alleviate localized heating and improve wear resistance. The cutting performance of the four saw-type tooth was further influenced by cutting depth and back rake angle, with optimal values identified as 1.5 mm and 20°, respectively. Compared with a conventional cutter, the four saw-type tooth design reduced the overall surface temperature by approximately 10.69%, with temperature rise confined mainly to the grooves between adjacent saw-type teeth and no widespread thermal concentration observed, confirming its design superiority. Full-scale rock-breaking simulations demonstrated that the bit equipped with four saw-type tooth achieved greater penetration depth and required lower torque than the conventional design, indicating enhanced rock-breaking ability and higher drilling efficiency. In conclusion, the four saw-type tooth PDC cutter design offers a promising approach for developing high-performance drill bits and reducing drilling costs.

In petroleum drilling, conventional automatic drilling systems still rely heavily on manual intervention, which often leads to poor stability, limited multivariable coordination, and large fluctuations in drilling pressure. To address this problem, this study develops a hydraulic drawworks-based autodriller system with integrated power, drive, actuation, and control units, and establishes a mechanical-hydraulic-control co-simulation model for the coordinated regulation of drill-string hoisting speed and surface weight-on-bit (SWOB). Based on this platform, a dual-loop control framework is developed in which the inner loop uses linear active disturbance rejection control (LADRC) for rapid disturbance estimation and compensation, while the outer loop uses PID control for tracking regulation. Feedforward compensation is introduced to handle predictable load variation, and PSO-assisted fuzzy tuning is used to improve adaptability under varying operating conditions. Simulation results show that, compared with conventional cascaded PID control, the proposed controller reduces drawworks speed and SWOB overshoot by 12.5% and 40%, respectively, while the corresponding settling times are shortened by 1.805 s and 2.443 s. Prototype experiments on a scaled test platform further show that the proposed controller can be implemented on physical hardware and can maintain stable real-time regulation under laboratory conditions. These results support the feasibility of the proposed framework for coordinated hydraulic drawworks control under the simulated and laboratory-scale conditions considered in this study.