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.

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.

scholarly journals Optimal design of a global force-balanced polycrystalline diamond compact bit considering wear condition

2019 ◽  
Vol 11 (12) ◽  
pp. 168781401989445
Author(s):  
Yachao Ma ◽  
Zhanghua Lian ◽  
Zhiqiang Huang ◽  
Wenlin Zhang ◽  
Dou Xie
Keyword(s):  
Oil And Gas ◽  
Polycrystalline Diamond ◽  
Bending Moment ◽  
Lateral Force ◽  
Force Model ◽  
Gas Drilling ◽  
Weight On Bit ◽  
Optimal Approach ◽  
Polycrystalline Diamond Compact ◽  
Wear Condition

Polycrystalline diamond compact bits are one of the most widely used oil and gas drilling tools in the world. With wear, a large unbalanced lateral force and bending moment exist. These force and moment contribute not only to bit lateral vibration and whirl but also to wellbore tilt and enlargement, which will then cause early bit failure and low drilling efficiency. In this article, considering wear condition, a single cutter force model is proposed. Lateral force and bending moment models are constructed based on space-force theory. An optimal cutter layout model considering cutter wear is established. The matching approach for the optimal model is discussed based on Kriging surrogate model and genetic algorithm. Then, an optimization case is presented. The results show that the bit force models are in line with the actual drilling condition. The optimal approach is efficient. After optimization, the lateral force to weight on bit ratio is reduced by 10.99%, and the bending moment to torque on bit ratio is reduced by 30.43%. This result is a significant improvement in the force condition and stability of the polycrystalline diamond compact bit; ultimately, the whirl and tilt motion can be reduced, and the drilling efficiency can be improved.

scholarly journals Application of an innovative ridge-ladder-shaped polycrystalline diamond compact cutter to reduce vibration and improve drilling speed

2020 ◽  
Vol 103 (3) ◽  
pp. 003685042093097
Author(s):  
Dou Xie ◽  
Zhiqiang Huang ◽  
Yuqi Yan ◽  
Yachao Ma ◽  
Yuan Yuan
Keyword(s):  
Oil And Gas ◽  
Polycrystalline Diamond ◽  
Rock Breaking ◽  
Drilling Process ◽  
Drilling Speed ◽  
Stick Slip ◽  
Gas Drilling ◽  
Drill Bits ◽  
Element Simulation ◽  
Polycrystalline Diamond Compact

Polycrystalline diamond compact bits have been widely used in the Oil and Gas drilling industry, despite the fact that they may introduce undesired vibration into the drilling process, for example, stick-slip and bit bounce, which accelerate the failure rate and lead to higher drilling costs. First, we develop an innovative ridge-ladder-shaped polycrystalline diamond compact cutter, which has ridge-shaped cutting faces and multiple cutting edges with stepped distribution, in the hope of reducing vibration and improving drilling speed. Then, the scrape tests of ridge-ladder-shaped and general polycrystalline diamond compact cutters are carried out in a laboratory, indicating that the cutting, lateral, and longitudinal forces on ridge-ladder-shaped polycrystalline diamond compact cutters are smaller and with minor fluctuations. Due to different rock-breaking mechanisms, ridge-ladder-shaped polycrystalline diamond compact cutters have higher cutting efficiency compared to general polycrystalline diamond compact cutters, which is also verified experimentally. Finally, the drilling characteristics of a new polycrystalline diamond compact bit fitted with some ridge-ladder-shaped polycrystalline diamond compact cutters are compared to those of a general polycrystalline diamond compact bit by means of finite element simulation. The results show that introducing ridge-ladder-shaped polycrystalline diamond compact cutters can not only reduce the stick-slip vibration, bit bounce, and backward rotation of drill bits effectively, but also improve their rate of penetration.

Finite Element Study of the Cutting Mechanics of the Three Dimensional Rock Turning Process

2015 ◽  
Author(s):  
Demeng Che ◽  
Jacob Smith ◽  
Kornel F. Ehmann
Keyword(s):  
Finite Element ◽  
Oil And Gas ◽  
Three Dimensional ◽  
Polycrystalline Diamond ◽  
Close Correlation ◽  
Experimental Results ◽  
Failure Behavior ◽  
Fe Model ◽  
Gas Drilling ◽  
Cutting Mechanics

The unceasing improvements of polycrystalline diamond compact (PDC) cutters have pushed the limits of tool life and cutting efficiency in the oil and gas drilling industry. However, the still limited understanding of the cutting mechanics involved in rock cutting/drilling processes leads to unsatisfactory performance in the drilling of hard/abrasive rock formations. The Finite Element Method (FEM) holds the promise to advance the in-depth understanding of the interactions between rock and cutters. This paper presents a finite element (FE) model of three-dimensional face turning of rock representing one of the most frequent testing methods in the PDC cutter industry. The pressure-dependent Drucker-Prager plastic model with a plastic damage law was utilized to describe the elastic-plastic failure behavior of rock. A newly developed face turning testbed was introduced and utilized to provide experimental results for the calibration and validation of the formulated FE model. Force responses were compared between simulations and experiments. The relationship between process parameters and force responses and the mechanics of the process were discussed and a close correlation between numerical and experimental results was shown.

Analytical Modeling of Heat Transfer in Polycrystalline Diamond Compact Cutters in Rock Turning Processes

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Demeng Che ◽  
Kornel Ehmann ◽  
Jian Cao
Keyword(s):  
Heat Transfer ◽  
Analytical Solution ◽  
Transfer Problem ◽  
Mixed Boundary ◽  
Separation Of Variables ◽  
Polycrystalline Diamond ◽  
Experimental Tests ◽  
Rock Cutting ◽  
Polycrystalline Diamond Compact ◽  
Temperature Responses

Heat transfer phenomena at the rock–cutter interface are extremely significant since they affect the polycrystalline diamond compact (PDC) cutter's performance in rock cutting/drilling processes. The understanding of how temperature and heat flux responses in the cutter influence the intrinsic mechanisms of the rock–cutter interactions is an essential prerequisite for providing insights to enhance the performance of PDC cutters and to optimize rock cutting/drilling processes. In this paper, a mixed boundary value heat transfer problem was formulated to analytically describe the heat transfer phenomena in the PDC cutters during two-dimensional (2D) orthogonal rock cutting under steady state conditions. An analytical solution in the form of an infinite series was derived based on the method of separation of variables, the use of appropriate simplifications in the formulated problem and the separation of the thermal from the mechanical phenomena. A series of experimental tests were conducted on a newly developed rock cutting testbed to calibrate the process parameters in the analytical solution and then to confirm the validity of the assumed boundary conditions. The comparison between the newly derived analytical solution and the experimental data shows a good match in terms of temperature responses during rock cutting performed by PDC cutters.

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.

Issues in Polycrystalline Diamond Compact Cutter–Rock Interaction From a Metal Machining Point of View—Part II: Bit Performance and Rock Cutting Mechanics

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Demeng Che ◽  
Peidong Han ◽  
Ping Guo ◽  
Kornel Ehmann
Keyword(s):  
Metal Cutting ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Point Of View ◽  
Rock Interaction ◽  
Metal Machining ◽  
Pdc Bit ◽  
Rock Cutting Mechanics ◽  
Cutting Processes ◽  
Polycrystalline Diamond Compact

In Part I of this paper, the issues related to temperature, stress and force were reviewed and parallels were drawn between both metal machining and rock cutting. Part II discusses the issues more directly related to polycrystalline diamond compact (PDC) bit performance and rock mechanics. However, relevant issues in various metal cutting processes will continue to be presented to clarify the gaps and similarities between these two classes of processes.

scholarly journals Simulation and Experimental Study of the Rock Breaking Mechanism of Personalized Polycrystalline Diamond Compact Bits

2020 ◽  
Vol 13 (5) ◽  
pp. 122-131
Author(s):  
Yu Jinping ◽  
◽  
Zou Deyong ◽  
Sun Yuanxiu ◽  
Zhang Yin
Keyword(s):  
Experimental Study ◽  
Finite Element ◽  
Tensile Stress ◽  
Crack Propagation ◽  
Tangential Force ◽  
Polycrystalline Diamond ◽  
Rock Breaking ◽  
Pdc Bit ◽  
Breaking Mechanism ◽  
Polycrystalline Diamond Compact

Rock breaking is a complex physical process that can be influenced by various factors, such as geometrical shape and cutting angle of rock breaking tools. Experimental study of the rock breaking mechanism of personalized bits is restricted due to long cycle and high cost. This study simulated the rock breaking mechanism of polycrystalline diamond compact (PDC) bit by combining finite element method and experiment. The simulation was performed to shorten the period and reduce the cost of studying the rock breaking mechanism of PDC bits. A rock breaking finite element model for sting cutters of personalized PDC bit was established to simulate the rock breaking process. The crack propagation pattern, dynamic stress of rock breaking, and rock breaking mechanism of sting cutters of personalized PDC bit were analyzed. The correctness of the simulation results was verified through experiments. Results demonstrate that the rock breaking load increases with the crack propagation in the fracture initiation and propagation stages, with the maximum tangential force of 1062.5 N and maximum axial force of 1850.0 N. The load changes in a small range when the crack penetrates the rock, with the tangential force of 125.0–500.0 N and axial force of 375.0–875.0 N. The rock breaking mechanism of the sting cutters of bit is consistent with maximum tensile stress theory. The rock begins to break when the tensile stress of rock is 36.9 MPa. The sting cutters of personalized PDC bit have better wear resistance than the sting cutters of conventional bit. The average wear rates of personalized PDC and conventional bits are 1.74E-4 and 2.1E-4 mm/m, respectively. This study serves as reference for shortening the study period of rock breaking mechanism, efficiently designing personalized PDC bit structure, reducing bit wear, and enhancing rock breaking efficiency.

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