Numerical Simulation Research on Cutting Rock with a PDC Cutter Assisted by an Impact Force

Wang, Yong; Ni, Hongjian; Wang, Ruihe; Huang, Bin; Liu, Shubin; Zhang, Heng

doi:10.1155/2022/8282104

Cited by 4 publications

(4 citation statements)

References 13 publications

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“…In this study, the focus lies on investigating the rock-breaking performance of the cutter under various schemes and parameter combinations. In order to enhance computational efficiency, it becomes necessary to exclude secondary factors and make the following assumptions [16,23]: (1) Due to the difference in hardness between the PDC cutter and the rock material, the wear of the cutter during rock breaking is ignored and considered a rigid body. (2) The rock is removed immediately upon breaking, and repeated PDC drill bit performance, PDC cutters of three different shapes, namely cylindrical, axe, and triangular prism, were designed using SOLIDWORKS 2021 software.…”

Section: Finite Element Model Assumptions and Evaluation Guidelinesmentioning

confidence: 99%

“…A systematic approach is crucial in the investigation of the rock-breaking process associated with PDC bits. Most of the current related studies, using experiments combined with numerical simulations [23], have greatly improved the accuracy of the simulations while reducing the research cost. However, most of the studies treat the rock as a homogeneous model during the numerical simulation, which does not reflect the real scenario of the actual drilling process.…”

Section: Introductionmentioning

confidence: 99%

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Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Yuan

Zhang

et al. 2023

Applied Sciences

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As the depth of petroleum drilling increases, the strata environment becomes more complex. The efficiency and lifespan of Polycrystalline Diamond Compact (PDC) drill bits fail to meet current drilling demands. However, the structure and arrangement of PDC cutters are valuable determinants of drilling efficiency, although related research still has gaps and deficiencies. This study focuses on PDC cutters in axe, triangular prism, and circular forms. It establishes an inhomogeneous granite model based on the actual measurements of granite and verifies the accuracy of this model through uniaxial compression simulation. Finite element models of three types of cutters in various combination schemes are constructed to examine rock-breaking effects, with the best scheme optimized using Box-Behnken response surface methodology. The rock-breaking process of the optimal PDC drill bit layout has been compared to that of a single cutter bit. Field drilling has demonstrated the effectiveness of a mixed cutter arrangement. The results show that the inhomogeneous granite model can be trusted. The optimal arrangement involves axe cutters in the front row and an alternate arrangement of triangular prism cutters and axe cutters in the back row. The optimal lateral and longitudinal distances for the triangular cutters from the front row of axe cutters are 10 mm and 7 mm, respectively, while those for the back row of axe cutters from the front row are 10.06 mm and 7 mm, respectively. The ROP standard deviation in the drilling process of mixed cutter bits decreases by 53.06% and 43.08% compared to axe and triangular prism cutter bits, respectively. The drilling efficiency increases by 16.8% and 16.6%, respectively, demonstrating higher efficiency and stability. Field drilling results indicate that a mixed cutter bit increases efficiency by 23.5% compared to a bit with only triangular prism cutters. This study posits that research on the combination schemes and parameters of PDC cutters can significantly enhance drilling efficiency, thereby reducing the drilling cycle and costs.

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Section: Finite Element Model Assumptions and Evaluation Guidelinesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Yuan

Zhang

et al. 2023

Applied Sciences

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“…In the process of PDC tooth cutting rock, the bulk cracking caused by rock brittleness is the main factor of its cutting force fluctuation. To simulate the fluctuation of cutting force [18,19], the cutting torque T ck and cutting WOB W ck are multiplied by a sawtooth function S ck . The torque T ck and W ck generated by the raw n tooth are expressed as follows:…”

Section: Improvement Of Pdc Bit-rock Contact Force Modelmentioning

confidence: 99%

An Improved Model to Characterize Drill-String Vibrations in Rotary Drilling Applications

Wang¹,

Ni²,

Wang³

et al. 2022

Fluid Dynamics &Amp; Materials Processing

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A specific model is elaborated for stick-slip and bit-bounce vibrations, which are dangerous dynamic phenomena typically encountered in the context of rotary drilling applications. Such a model takes into account two coupled degrees of freedom of drill-string vibrations. Moreover, it assumes a state-dependent time delay and a viscous damping for both the axial and torsional vibrations and relies on a sawtooth function to account for the cutting force fluctuation. In the frame of this theoretical approach, the influence of rock brittleness on the stability of the drill string is calculated via direct integration of the model equations. The results show that the rock brittleness has a great influence on the rotational speed and bit depth.

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“…The impact frequency can also be ranked to establish performance thresholds depending on the characteristics of the equipment and drilling surface. The work in [11] shows that when impact frequency is lower than the threshold frequency, the detritus removal volume is reduced in the rock breaking process considering polycrystalline diamond drill bits.…”

Section: Introductionmentioning

confidence: 99%

Identification of Impact Frequency for Down-the-Hole Drills Using Motor Current Signature Analysis

et al. 2023

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In rotary-percussion drilling, the impact frequency is a crucial variable that is closely linked to operational factors that determine the efficacy of the drilling process, such as the rate of penetration, bit wear, and rock mass characteristics. Typical identification methods rely on complex simulation models or the analysis of different sensor signals installed on specially adapted setups, which are difficult to be implemented in the field. This paper presents a novel study where the impact frequency is identified by motor current signature analysis (MCSA) applied to an induction motor driving a DTH drilling setup. The analysis of the case study begins with the definition of characteristic drilling stages where the pressure and sound signals allow the detection of an impact frequency of 14.10 Hz, which is then used as a reference to validate three MCSA identification approaches. As a result of the analysis, the envelope approach is the most robust for nearly real-time implementations considering its simplicity and range of coverage. Experimental results provide evidence about the feasibility of the proposed MCSA methods to be integrated into Measurement-While-Drilling (MWD) systems to improve drilling condition monitoring and rock mass characterization.

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Numerical Simulation Research on Cutting Rock with a PDC Cutter Assisted by an Impact Force

Cited by 4 publications

References 13 publications

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

An Improved Model to Characterize Drill-String Vibrations in Rotary Drilling Applications

Identification of Impact Frequency for Down-the-Hole Drills Using Motor Current Signature Analysis

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