Experimental investigation of the rock cutting process with blunt PDC cutters

Liu, Weiji; Deng, Hongxing; Liu, Yuming; Chen, Xinwu; He, Chao; Zhu, Xiaohua

doi:10.1016/j.geoen.2023.211803

Cited by 6 publications

(2 citation statements)

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“…This implies that an increase in cutting depth results in a decrease in the efficiency of the rock-breaking process. The reason for this is that as the cutting depth increases, the rock undergoes a transition from plastic deformation to brittle fracture, leading to a reduction in the efficiency of the rock-breaking process [6]. Although the volume of fragmented rock increases, the removal of rock by the cutter requires more energy due to increased frictional forces, resulting in a decrease in rock-breaking efficiency.…”

Section: Effect Of Back Rake Angle On Cutter Rock Breakingmentioning

confidence: 99%

“…The development of unconventional oil and gas resources is on the rise, and the depth of oil drilling has gradually extended from shallow to deep and even ultra-deep formations [4,5]. As the drilling depth increases, the formation's drill ability deteriorates, and the high abrasiveness and hardness of the formation limit the performance of PDC drill bits [6]. Traditional PDC drill bits encounter approximately 40% superior to that of conventional cutters.…”

Section: Introductionmentioning

confidence: 99%

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Structure Design of Bionic PDC Cutter and the Characteristics of Rock Breaking Processes

Wu,

Yuan,

Zhang

et al. 2023

Processes

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The rational structural design of polycrystalline diamond compact (PDC) cutters effectively enhances the performance of drill bits in rock fragmentation and extends their service life. Inspired by bionics, a bionic PDC cutter was designed, taking the mole claw toe, shark tooth, and microscopic biomaterial structures as the bionic prototypes. To verify its rock-breaking effectiveness, the finite element method was employed to compare the rock-breaking processes of the bionic cutter, triangular prism cutter, and axe cutter. The study also investigated the influence of different back rake angles, cutting depths, arc radii, and hydrostatic pressures on rock breaking using the bionic cutter. Prior to this, the accuracy of the finite element model was validated through laboratory tests. Subsequently, a drill bit incorporating all three types of cutters was constructed, and simulations of rock breaking were conducted on a full-sized drill bit. The results demonstrate that the bionic cutter exhibits superior load concentration on the rock compared to the triangular prism cutter and the axe cutter. Additionally, its arc structure facilitates the “shoveling” of the rock, making it more susceptible to breakage under tensile stress. As a result, the efficiency of the bionic cutter surpasses that of the triangular prism and axe cutters. Similarly, it exhibits minimal fluctuations and values in cutting force. As the back rake angle and cutting depth increase, the MSE and cutting force of all three cutters also increase. However, the bionic cutter consistently maintains the lowest MSE and cutting force, confirming the superiority of its bionic structural design. The MSE and cutting force of the bionic cutter fluctuate with the increase of the arc radius, and the optimal arc radius falls within the simulation range, between 21 mm and 23 mm. Compared to the other two types of cutters, bionic cutters possess a unique structure that allows for better release of internal stress within the rock, thereby ensuring higher efficiency in rock-breaking, particularly in deep geological formations. The rock breaking simulation results of full-sized drill bits show that the use of a bionic cutter can improve the drill bit’s ability to penetrate the formation, reduce the possibility of drill bit bounce during the rock breaking process, prevent the occurrence of stick-slip, improve the drilling stability, effectively improve the efficiency and service life of the drill bit during the rock breaking process, and reduce the drilling cost. It is concluded that the research results of bionic PDC cutters are helpful to the development of high-performance drill bits and the reduction of drilling costs.

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Section: Effect Of Back Rake Angle On Cutter Rock Breakingmentioning

confidence: 99%