Influence of Friction and Rake Angle on the Formation of Discontinuous Rock Fragments During Rock Cutting

2010 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell ◽  
C. Fred Higgs
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Rock Cutting ◽  
Rake Angle ◽  
Rock Material ◽  
Fragmentation Process ◽  
Rock Fragment ◽  
Explicit Finite Element ◽  
Rock Fragments

Tribological properties during rock cutting under extremely high pressure and high temperature (HPHT) conditions are important in deep mining and drilling operations. In the present investigation, a rock fragmentation process is simulated during mechanical cutting of rock using an explicit finite element code, LS-DYNA. In the simulations, a rigid steel cutting tool of different rake angles was moved at different velocities against a stationary rock material. Rock material properties have been incorporated using an advanced damage constitute material model. In addition, the friction factors at the cutting tool–rock interface were varied in the contact model. The variation of cutting forces, stresses and rock fragment morphology have been investigated. Overall, the results indicate that the explicit finite element model is a powerful tool for simulating rock cutting and the fragmentation process. More specifically, the separation of rock fragments from the rock slab was accurately predicted using the numerical model. The rake angle was found to have significant influence on the fragment morphology during rock cutting. Moreover, the cutting forces and the discontinuous fragmentation process were strongly influenced by the friction and cutting velocity.

Influence of Rock Mechanical Properties on the Formation of Rock Fragments During Cutting Operation

2011 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell
Keyword(s):  
Mechanical Properties ◽  
Cutting Forces ◽  
Numerical Models ◽  
Cutting Parameters ◽  
Rock Cutting ◽  
Rake Angle ◽  
Rock Fragmentation ◽  
Oil Well ◽  
Explicit Finite Element ◽  
Rock Mechanical Properties

Mechanical rock cutting is a process encountered in different engineering applications including rock excavation, mining and deep oil well drilling. Rock mechanical properties vary with depth in the subsurface and also at different geographical locations due to different environmental conditions. Understanding of fragmentation mechanisms in specific rock materials allows the determination of optimum cutting parameters that improve cutting efficiency and increase tool life during cutting operations. In the present investigation, numerical models that accurately predict the rock fragmentation and stress profiles in the rock slab during cutting were developed using the explicit finite-element method (FEM). In the numerical models, a damage material model was utilized to capture the rock fragmentation process and a rigid steel cutter (at different rake angles) was displaced at different velocities against a stationary rock slab. Rock slabs with significantly different mechanical properties were incorporated with a constant friction factor and a cutting depth of 1 mm. The variation of cutting forces and stresses, and fragmentation of the rock slab were analyzed. The simulation results indicated that the explicit FEM is a powerful tool for simulating rock cutting as the formation of fragments were distinctly observed at different cutting conditions. The rock mechanical properties and tool rake angle were found to have the most significant effect on the rock fragmentation during cutting operations. The cutting forces were also influenced by mechanical properties of the rock and tool rake angle.

Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics

2000 ◽  
Vol 124 (1) ◽  
pp. 32-41 ◽  
Author(s):  
D. Arola ◽  
M. B. Sultan ◽  
M. Ramulu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Deformable Body ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Tool Geometry ◽  
Reinforced Plastics ◽  
Edge Trimming

A finite element model was developed to simulate chip formation in the edge trimming of unidirectional Fiber Reinforced Plastics (FRPs) with orthogonal cutting tools. Fiber orientations (θ) within the range of 0 deg⩽θ⩽90 deg were considered and the cutting tool was modeled as both a rigid and deformable body in independent simulations. The principal and thrust force history resulting from numerical simulations for orthogonal cutting were compared to those obtained from edge trimming of unidirectional Graphite/Epoxy (Gr/Ep) using polycrystalline diamond tools. It was found that principal cutting forces obtained from the finite element model with both rigid and deformable body tools compared well with experimental results. Although the cutting forces increased with increasing fiber orientation, the tool rake angle had limited influence on cutting forces for all orientations other than θ=0 deg and 90 deg. However, the tool geometry did affect the degree of subsurface damage resulting from interlaminar shear failure as well as the cutting tool stress distribution. The finite element model for chip formation provides a means for optimizing tool geometry over the total range in fiber orientations in terms of the cutting forces, degree of subsurface trimming damage, and the cutting tool stresses.

scholarly journals The Calculation of the Tensely Strained State of the System «Diamond Bit-Bottom»

2015 ◽  
Vol 9 (11) ◽  
pp. 203
Author(s):  
Aigerim E. Assan ◽  
Yury E. Budyukov ◽  
Vladislav P. Onishin ◽  
Vitaly V.Povetkin ◽  
Toktasin M. Mendebayev
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Tool ◽  
Rock Cutting ◽  
External Loading ◽  
Drill Bit ◽  
Strained State ◽  
Geological Conditions ◽  
Diamond Bit ◽  
Element Method

<p class="zhengwen">The design procedure of the tensely strained state(TSS) of the system <strong>«</strong>diamond bit-bottom<strong> » </strong>is developed, basic analytical dependences, characterizing TSS of the system of the calculation the basic parameters-tension, strains under the influence of an external loading on the diamond bit with finite-element method application (FEM) are chosen in the offered article. The questions of the creation in plane posing with usage of share the block - schema of the program, realizing finite-element method. For components of the process of interaction with a diamond bit rock used the method of mathematical modeling of components of the process (partial solutions) output data which will be the main characteristics of the process, allow to formulate requirements for the development of the diamond rock cutting tool.</p> <p class="zhengwen">And also addressed the issues of creating a removable drill bit used for boring exploration wells are considered in the article. The authors propose a technological solution for the modernization and improvement of removable drill bit, taking into account the various stages of deterioration of diamond bits.</p> The possibility of improving the diamond destructive tool, including a special on the scientific, engineering and technological level are far from exhausted. Diamond drilling in difficult geological conditions accompanied not enough efficient use of energy supplied to the face, the working face of overheating matrices crowns, abnormal wear of the rock cutting tool, and is not always suitable geological work quality. In this context, the relevance of the set objectives in this paper is quite obvious.

Studies on the formation of discontinuous chips during rock cutting using an explicit finite element model

2013 ◽  
Vol 70 (1-4) ◽  
pp. 635-648 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell ◽  
Ilya V. Avdeev ◽  
Jeen-Shang Lin ◽  
C. Fred Higgs
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Rock Cutting ◽  
Explicit Finite Element

Finite Element Analysis of Tool Stresses, Temperature and Prediction of Cutting Forces in Turning Process

2017 ◽  
Vol 261 ◽  
pp. 354-361 ◽  
Author(s):  
Martin Necpal ◽  
Peter Pokorný ◽  
Marcel Kuruc
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Element Model ◽  
Turning Process ◽  
Element Analysis ◽  
Tool Stresses ◽  
Chip Separation ◽  
Carbide Insert

The paper presents the simulation model of turning the process of C45 non-alloy steel with a tool made of carbide insert. A 3D final element model used a lagrangian incremental type and re-meshing chip separation criterion was experimentally verified by measure cutting forces using piezoelectric dynamometer. In addition, stresses and temperature in the tooltip were predicted and examine. This work could investigate failure the tooltip, which would be great interest to predict wear and damage of cutting tool.

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