Nickel-based alloy is difficult-to-machine because of its low thermal diffusive property and high strength at higher temperature. The machinability of nickel-based Hastelloy C-276 in turning operations has been carried out using different types of inserts under dry conditions on a computer numerical control (CNC) turning machine at different stages of cutting speed. The effects of cutting speed on surface roughness have been investigated. This study explores the types of wear caused by the effect of cutting speed on coated and uncoated carbide inserts. In addition, the effect of burr formation is investigated. The chip burr is found to have different shapes at lower speeds. Triangles and squares have been noticed for both coated and uncoated tips as well. The conclusion from this study is that the transition from thick continuous chip to wider discontinuous chip is caused by different types of inserts. The chip burr has a significant effect on tool damage starting in the line of depth-of-cut. For the coated insert tips, the burr disappears when the speed increases to above 150 m/min with the improvement of surface roughness; increasing the speed above the same limit for uncoated insert tips increases the chip burr size. The results of this study showed that the surface finish of nickel-based alloy is highly affected by the insert type with respect to cutting speed changes and its effect on chip burr formation and tool failure.
This study focuses on numerical simulation and evaluation of a hydraulically powered downhole Thruster. This device is numerically simulated and evaluated using ANSYS Fluent 17.2 to show its generation of pressure pulses that can induce downhole forces that magnify the downhole dynamic weight on bit (DWOB) using drilling mud. Such magnification of the DWOB can produce axial motion of the Thruster. Such axial motions, as proved by many publications can improve the drilling rate of penetration (ROP), release stuck pipes, and reduce frictions in non-vertical wells. The special inner design of the Thruster creates pressure pulses that can provide load impact on the drill bit leading to the increase of WOB that can enhance the drilling performance. The current stage of the study of the Thruster involves a mechanical design of the Thruster by the SolidWorks and an evaluation of the tool function and performance through pressure effect simulation by ANSYS Fluent 17.2. Initially, water is used as the fluid and the main parameters involved in the analysis are pressure and velocity. However, power-law as a non-Newtonian fluid is also used for comparison study in the section of pressure drop analysis.
The results are analyzed based on velocity pressure profiles, pressure drops, pressure effects with applications of various back pressures at several planes using water and power-law fluids.
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