The Effect on Cutting Tool Forces of Pre-Weakening a Rock Surface by Waterjet Kerfing

1989 ◽  
Vol 111 (1) ◽  
pp. 1-6
Author(s):  
J. E. Geier ◽  
M. Hood
Keyword(s):  
Unit Volume ◽  
Cutting Tool ◽  
Normal Force ◽  
Mechanical Energy ◽  
Polycrystalline Diamond ◽  
Empirical Models ◽  
Depth Of Cut ◽  
Rock Surface ◽  
Mechanical Specific Energy ◽  
Polycrystalline Diamond Compact

Empirical models are developed to describe the influence on the cutting process of preweakening a rock, by cutting a series of parallel kerfs in the surface with high pressure waterjets, prior to excavating the rock with a polycrystalline diamond compact (PDC) drag bit. These models show that both the bit cutting force and the bit normal force are reduced substantially (by as much as a factor of four) when the spacing and the depth of the kerfs is appropriate to the depth of cut taken by the bit. The mechanical specific energy, or the mechanical energy applied to the bit to excavate a unit volume of rock, is also reduced dramatically when the rock is prekerfed.

Relative Significance of Multiple Parameters on the Mechanical Specific Energy and Frictional Responses of Polycrystalline Diamond Compact Cutters

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Babak Akbari ◽  
Stefan Z. Miska
Keyword(s):  
Specific Energy ◽  
Polycrystalline Diamond ◽  
Friction Angle ◽  
Rake Angle ◽  
Fractional Factorial ◽  
Depth Of Cut ◽  
Relative Significance ◽  
Mechanical Specific Energy ◽  
Wellbore Pressure ◽  
Polycrystalline Diamond Compact

A high pressure single polycrystalline diamond compact (PDC) cutter testing facility was used to investigate the effect of five factors on PDC cutter performance on Alabama marble. The factors include: depth of cut (DOC), rotary speed, back rake angle, side rake angle, and confining (wellbore) pressure. The performance is quantified by two parameters: mechanical specific energy (MSE) and friction angle. Fractional factorial design of experiments methodology was used to design the experiments, enabling detection of potential interactions between factors. Results show that, in the range tested, the only statistically significant factor affecting the MSE is DOC. In other words, DOC's influence is predominant and it can mask the effect of all the other factors. These results could have applications in real time pore pressure detection. Further, the results show that back rake angle is the most statistically significant factor in friction angle. Side rake angle and depth of cut also affect the friction angle, but in a relatively unimportant manner. The MSE–DOC behavior is explained and modeled by cutter edge–groove friction and the circular cutter shape. It is speculated that high cutter edge friction overwhelms the actual cutting process. A comparison of five currently present models in the literature with these results is presented and the conclusion is that the future PDC cutter models should digress from the traditional shear failure plane models.

Rock Cutter Interactions in Linear Rock Cutting

2016 ◽  
Author(s):  
Demeng Che ◽  
Weizhao Zhang ◽  
Kornel F. Ehmann
Keyword(s):  
Experimental Data ◽  
Oil And Gas ◽  
Cutting Tool ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Testing Methods ◽  
Gas Drilling ◽  
Complex Interactions ◽  
On Chip ◽  
Polycrystalline Diamond Compact

Polycrystalline diamond compact (PDC) cutter, as a major cutting tool, has been widely applied in oil and gas drilling processes. The understanding of the complex interactions at the rock and cutter interfaces are essential for the advancement of future drilling technologies, yet, these interactions are still not fully understood. Linear cutting of rock, among all the testing methods, avoids the geometric and process complexities and offer the most straightforward way to reveal the intrinsic mechanisms of rock cutting. Therefore, this paper presents an experimental study of the cutter’s cutting performance and the rock’s failure behaviors on a newly developed linear rock cutting facility. A series of rock cutting tests were designed and performed. The acquired experimental data was analyzed to investigate the influences of process parameter and the rock’s mechanical properties on chip formation and force responses.

Chip Formation and Force Responses in Linear Rock Cutting: An Experimental Study

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Demeng Che ◽  
Weizhao Zhang ◽  
Kornel Ehmann
Keyword(s):  
Experimental Study ◽  
Chip Formation ◽  
Oil And Gas ◽  
Cutting Tool ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Gas Drilling ◽  
Complex Interactions ◽  
On Chip ◽  
Polycrystalline Diamond Compact

Polycrystalline diamond compact (PDC) cutters, as a major cutting tool, have been widely applied in oil and gas drilling processes. The understanding of the complex interactions at the rock and cutter interfaces is essential for the advancement of future drilling technologies; yet, these interactions are still not fully understood. Linear cutting of rock, among all the testing methods, avoids the geometric and process complexities and offers the most straightforward way to reveal the intrinsic mechanisms of rock cutting. Therefore, this paper presents an experimental study of the cutter’s cutting performance and the rock’s failure behaviors on a newly developed linear rock cutting facility. A series of rock cutting tests were designed and performed. The acquired experimental data was analyzed to investigate the influences of process parameters and the rock’s mechanical properties on chip formation and force responses.

Si Particle Size-Controlled Al-17 Mass% Si Alloy and Tool Wear in Cutting Al-17 Mass% Si Alloy by Polycrystalline Diamond Compact Cutting Tool

2015 ◽  
Vol 798 ◽  
pp. 372-376
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Water Cooling ◽  
Cooling Speed ◽  
High Silicon ◽  
Polycrystalline Diamond Compact

As high silicon aluminum alloys have both a high strength-to-weight ratio and good wear-resistance, they are used for many automobile and motorbike parts. High silicon aluminum alloys are generally machined to improve dimensional accuracy. In cutting high silicon aluminum alloys such as Al-17mass%Si alloy, the primary Si particles have a negative influence on tool wear. Therefore, polycrystalline diamond compact cutting tools are widely used. In this study, in order to improve the tool wear resistance of polycrystalline diamond compact cutting tools, the Si particle size of Al-17 mass% Si alloy was changed by adjusting the water-cooling speed. Two different kinds of Si particle size, which were changed by adjusting the water-cooling speed, were used. The Al-17mass%Si alloy was turned with the polycrystalline diamond compact cutting tool and the tool wear was experimentally investigated. The main results were as follows: (1) The formed Si particle size was from 30 to 70 μm or from 40 to 170 μm. (2) The mechanical properties of the Al-17 mass% Si alloy did not depend on the Si particle size. (3) The Si particle size included in the Al-17 mass% Si alloy had a major influence of the tool wear, and it was possible to reduce the tool wear by increasing the Si particle size including that in the Al-17 mass% Si alloy.

Microturning of landing gear components used in miniature unmanned aircraft vehicles

2018 ◽  
Vol 1 (1) ◽  
pp. 20-44 ◽  
Author(s):  
M. J. Jackson ◽  
J. Burgess
Keyword(s):  
Cutting Tool ◽  
Polycrystalline Diamond ◽  
Landing Gear ◽  
Unmanned Aircraft ◽  
Depth Of Cut ◽  
Variable Geometry ◽  
The Finite Element Method ◽  
Thermal Camera ◽  
Machining Forces ◽  
Different Levels

The microturning of landing gear components used in miniature unmanned aircraft vehicles is described in this article. The finite element method (FEM) is used to predict variables such as microturning forces and temperatures at two different levels of roughing cut (1 and 3 mm depth of cut) with variable geometry cutting tool inserts. The predicted results are compared to experimentally determined magnitudes of forces and temperatures using a dynamometer and an infrared thermal camera. The results show that tool inserts with novel chip breaker functions reduce the magnitude of the machining forces and temperatures predicted using the FEM and validated by performing controlled experiments using Al-380 aluminum alloys machined with polycrystalline diamond-coated cutting tool inserts.

Study on Wafer Thinning Characteristics of Ultimate Diamond Disk

2012 ◽  
Vol 591-593 ◽  
pp. 476-479
Author(s):  
Xu Xing Jin
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Diamond Disk ◽  
Diamond Cutting Tools ◽  
Wafer Thinning ◽  
Wafer Surfaces

Silicon wafer is machined by diamond cutting tools to certain extent, the cutting tool currently used is polycrystalline diamond (PCD). However, as its cutting edges are not leveled to the same height, it will produce different depth of cut and the stress distribution is uneven on wafer surfaces, in the process of wafer thinning, both the workpiece and the cutting tool are probably damaged, this will increase the production cost accordingly. In this paper, a strategy is described to improve the ability of cutting tool for wafer thinning, a cutting tool named Ultimate Diamond Disk (UDD) designed by Taiwan Wheel Company is recommended, which can reduce both the crack of workpiece and the wear speed of cutting tool. Moreover, an experiment on base of different machining parameters including rotation speed of spindle, feed rate and depth of cut was tested and discussed. As a result, the removal mode of workpiece material and the wafer thinning characteristics of UDD are obtained.

scholarly journals A new approach to evaluate rock drillability of polycrystalline diamond compact bits using scratch test data

2020 ◽  
Vol 38 (4) ◽  
pp. 884-904 ◽  
Author(s):  
Yannong Han ◽  
Xiaorong Li ◽  
Yongcun Feng
Keyword(s):  
Specific Energy ◽  
Polycrystalline Diamond ◽  
New Method ◽  
New Model ◽  
The Core ◽  
Mechanical Specific Energy ◽  
Rock Drillability ◽  
Micro Drilling ◽  
Scratch Tests ◽  
Polycrystalline Diamond Compact

Rock drillability is a comprehensive index that indicates the ease of drilling a hole in the rock mass, which is a main basis for the design of drilling bits, the optimization of drilling operational parameters, and the prediction of rate of penetration. This paper established a conversion relationship between mechanical specific energy measured from micro-drilling tests and mechanical specific energy measured from scratch tests, based on the consistency of rock breaking mechanism between these two types of tests. By incorporating the methodology of calculating rock drillability grade of polycrystalline diamond compact bits, a new mathematical model for predicting rock drillability of polycrystalline diamond compact bits is developed. Subsequently, a new method for acquiring continuous rock drillability profile by scratching the core surface is developed. A wide range of rocks with different hardness were tested by the proposed scratch method. The results show that the new model has high consistency with the results of laboratory micro-drilling tests. For example, the average errors of sandstone, shale, and carbonate test results are only 7.41%, 8.18%, and 4%, respectively. The new method can fully characterize the effect of mineral composition, cementation strength, and microstructure of rock on drillability. Besides, the new model has high utilization efficiency of expensive core samples because the core usually remains nondestructive after scratch tests.

scholarly journals Machinability of Rolled Aluminum using Advanced Coated Cutting Tools and its Characterization

2019 ◽  
Vol 8 (3) ◽  
pp. 776-783
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Diamond Tool ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
Constant Depth ◽  
Rolled Aluminum ◽  
Polycrystalline Diamond Inserts

Because of multiple properties like higher values of corrosion resistance, formability, weldability along with greater structural utility aluminum alloys are generally gaining more and more demand in industries and household. With this the requirement for searching of higher quality cutting tool to machine aluminum is also growing. Here different cutting tools like MTCVD+TiCN+Al2O3 , MTCVD+TiCN+Al2O3+TiOCN, MTCVD+TiN+TiCN+Al2O3+TiN, PVD AlTiN, cemented carbide (k-10) insert brazed with Polycrystalline Diamond and Polycrystalline Diamond Inserts are being used to machine rolled aluminum in dry condition and then comparative analysis are made. The cutting is of orthogonal type and capstan lathe is used for the same. Under different conditions of cutting the surface roughness along with morphology of chip are analyzed. Under constant depth of cut (doc) along with variable velocities and feed, the turning operation is performed. With SEM and XRD the identification including characterization of cutting tool were also performed. The polycrystalline diamond tool is found to give optimum surface finish, thin type of chip along with mirror like finish during machining operation.

Sign in / Sign up

Export Citation Format

Share Document