Novel Drill Bit Analysis to Delay and Mitigate Fixed Cutter Thermal Damage

2021 ◽  
Author(s):  
Sion Llywelyn Roberts ◽  
Michael James Bailey ◽  
Afshin Babaie Aghdam ◽  
Ahmed Suleiman ◽  
Ahmed Fathy
Keyword(s):  
Cooling Rate ◽  
Design Process ◽  
Thermal Damage ◽  
Drilling Process ◽  
Drill Bit ◽  
Operational Parameters ◽  
Thermal Index ◽  
Testing Phase ◽  
Index Analysis ◽  
Input Load

Abstract As oil and gas wells become deeper, drilling longer intervals is becoming a major milestone for drill bit companies, as the process comes with a variety of challenges affecting the durability of drill bits. Among the major challenges are thermal and impact damage in polycrystalline diamond compact (PDC) cutters, which can significantly affect the performance and longevity of a drill bit. While cutter technology development remains an important arena to address said challenges, there exists a need to also address these through the design process. This paper presents the development and deployment of a new drill bit analysis method that addresses thermal damage by optimizing the design, which has been field validated across the globe. The analysis involves estimating the thermal input load and the available cooling rate for every cutter on a drill bit during drilling conditions. The data is then used to optimize and apply changes to the design. The analysis considers all the critical and relevant operational parameters to calculate these indices. The outcome of the so-called thermal index analysis enables the design team to make informed decisions to improve the design of the drill bit and to minimize the extent of thermal damage in cutters. The improvements made in the design include changes in cutting structure to affect cutting forces and, eventually, the thermal input load during the drilling process. This stage in practice can bring down the temperature of the cutting edge by 20%, as calculated analytically. Another major change that can affect the results is hydraulic design of the bit, which includes the location of the nozzles as well as their orientation and size. In test cases, the cooling rate improved by 50% while keeping the same flow rate though the bit. Several field trials have validated the correlation of thermal index analysis to drill bit dulls. This analysis is now in the field evaluation and testing phase, where it is being used during the design process to improve bits with thermal damage. The field-testing phase has been primarily conducted in thermally challenging applications across the Middle East, North Africa region, and in West Texas.

scholarly journals Change of the Properties of Steel Material of the Roller Cone Bit Due to the Influence of the Drilling Operational Parameters and Rock Properties

Energies ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5949
Author(s):  
Jurij Šporin ◽  
Tilen Balaško ◽  
Primož Mrvar ◽  
Blaž Janc ◽  
Željko Vukelić
Keyword(s):  
Structural Changes ◽  
Simultaneous Thermal Analysis ◽  
Rock Properties ◽  
Drilling Process ◽  
Drill Bit ◽  
Operational Parameters ◽  
Rock Materials ◽  
Steel Material ◽  
Drilling Parameters ◽  
Bit Life

The breakdown of the drill bit or rapid decrease of the rate of penetration during the drilling process results in a delay in the progress of drilling. Scientists and engineers are increasingly focusing on research to extend the bit life and improve the drilling rate. In our work, “in situ” drilling parameters were monitored during the drilling process with the roller cone drill bit IADC 136, diameter 155.57 mm (6 1/8"). After drilling, the bit was thoroughly examined to determine the damage and wear that occurred during drilling. The following modern and standardized investigative methods were used: an analysis of rock materials and an analysis of micro and macrostructure materials of the roller cone bit. Analyses were carried out using optical and electron microscopy, a simultaneous thermal analysis of materials of drill bit, analysis of the chemical composition of materials of drill bit, and a determination of the geomechanical parameters of rock materials. The resulting wear, local bursts, and cracks were quantitatively and qualitatively defined and linked to the drilling regime and the rock material. The results of our investigation of the material of the roller cone bit can serve as a good base for the development of new steel alloys, which can resist higher temperatures and enable effective drilling, without structural changes of steel material.

Machinability study and optimization of CNC drilling process parameters for HSLA steel with coated and uncoated drill bit

2021 ◽  
Author(s):  
Nitin P. Sherje ◽  
Sameer A. Agrawal ◽  
Ashish M. Umbarkar ◽  
Prashant P. Kharche ◽  
Dharmesh Dhabliya
Keyword(s):  
Process Parameters ◽  
Hsla Steel ◽  
Drilling Process ◽  
Drill Bit

Study of stick–slip suppression and robustness to parametric uncertainty in drill strings containing torsional vibration tool using sliding-mode control

2021 ◽  
pp. 146441932110452
Author(s):  
Jialin Tian ◽  
Jie Wang ◽  
Siqi Zhou ◽  
Yinglin Yang ◽  
Liming Dai
Keyword(s):  
Torsional Vibration ◽  
Complex Dynamics ◽  
Sliding Mode ◽  
Parametric Uncertainty ◽  
Drill String ◽  
Lumped Parameter Model ◽  
Drilling Process ◽  
Drill Bit ◽  
Stick Slip ◽  
Drilling Operations

Excessive stick–slip vibration of drill strings can cause inefficiency and unsafety of drilling operations. To suppress the stick–slip vibration that occurred during the downhole drilling process, a drill string torsional vibration system considering the torsional vibration tool has been proposed on the basis of the 4-degree of freedom lumped-parameter model. In the design of the model, the tool is approximated by a simple torsional pendulum that brings impact torque to the drill bit. Furthermore, two sliding mode controllers, U1 and U2, are used to suppress stick–slip vibrations while enabling the drill bit to track the desired angular velocity. Aiming at parameter uncertainty and system instability in the drilling operations, a parameter adaptation law is added to the sliding mode controller U2. Finally, the suppression effects of stick–slip and robustness of parametric uncertainty about the two proposed controllers are demonstrated and compared by simulation and field test results. This paper provides a reference for the suppression of stick–slip vibration and the further study of the complex dynamics of the drill string.

scholarly journals Optimization of Drilling Process Parameters Via Taguchi, TOPSIS and RSA Techniques

2017 ◽  
Vol 62 (3) ◽  
pp. 1803-1812 ◽  
Author(s):  
K. Shunmugesh ◽  
K. Panneerselvam
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Speed ◽  
High Strength ◽  
Drilling Process ◽  
Drill Bit ◽  
Influence Of Process Parameters ◽  
Light Trucks ◽  
Cfrp Composite

AbstractCarbon Fiber Reinforced Polymer (CFRP) is the most preferred composite material due to its high strength, high modulus, corrosion resistance and rigidity and which has wide applications in aerospace engineering, automobile sector, sports instrumentation, light trucks, airframes. This paper is an attempt to carry out drilling experiments as per Taguchi’s L27(313) orthogonal array on CFRP under dry condition with three different drill bit type (HSS, TiAlN and TiN). In this research work Response Surface Analysis (RSA) is used to correlate the effect of process parameters (cutting speed and feed rate) on thrust force, torque, vibration and surface roughness. This paper also focuses on determining the optimum combination of input process parameter and the drill bit type that produces quality holes in CFRP composite laminate using Multi-objective Taguchi technique and TOPSIS. The percentage of contribution, influence of process parameters and adequacy of the second order regression model is carried out by analysis of variance (ANOVA). The results of experimental investigation demonstrates that feed rate is the pre-dominate factor which affects the response variables.

Multiple Rock Breakdown in Electrodischarge Technology

2016 ◽  
Vol 712 ◽  
pp. 55-59
Author(s):  
Vladislav M. Vazhov ◽  
Sergey Y. Datskevitch ◽  
Mikhail Y. Zhurkov ◽  
Vasily M. Muratov ◽  
Arild Rødland
Keyword(s):  
Electric Discharge ◽  
High Voltage ◽  
Voltage Pulse ◽  
Rock Fracture ◽  
High Voltage Pulse ◽  
Electric Strength ◽  
Drilling Process ◽  
Drill Bit ◽  
Research Outcomes ◽  
Experimental Technology

The article covers the research of the electric strength and fracture of rocks that are undergone multiple breakdowns generated by electric discharge rock fracture and drilling technologies. The research outcomes allow proposing an experimental technology able to determine operating high voltage pulse values in the electric discharge drilling process where one should take into account such factors as the rock re-crushing and the drill bit shift cyclicity.

Drilling of bone: Effect of drill bit geometries on thermal osteonecrosis risk regions

2018 ◽  
Vol 233 (2) ◽  
pp. 207-218 ◽  
Author(s):  
Mohd Faizal Ali Akhbar ◽  
Ahmad Razlan Yusoff
Keyword(s):  
Ex Vivo ◽  
Helix Angle ◽  
Simulation Software ◽  
Drilling Process ◽  
Drill Bit ◽  
Temperature Elevation ◽  
Bone Drilling ◽  
Drilling Simulation ◽  
Deform 3D ◽  
Bone Effect

Bone-drilling operation necessitates an accurate and efficient surgical drill bit to minimize thermal damage to the bone. This article provides a methodology for predicting the bone temperature elevation during surgical bone drilling and to gain a better understanding on the influences of the point angle, helix angle and web thickness of the drill bit. The proposed approach utilized the normalized Cockroft–Latham damage criterion to predict material cracking in the drilling process. Drilling simulation software DEFORM-3D is used to approximate the bone temperature elevation corresponding to different drill bit geometries. To validate the simulation results, bone temperature elevations were evaluated by comparison with ex vivo bone-drilling process using bovine femurs. The computational results fit well with the ex vivo experiments with respect to different drill geometries. All the investigated drill bit geometries significantly affect bone temperature rise. It is discovered that the thermal osteonecrosis risk regions could be reduced with a point angle of 110° to 140°, a helix angle of 5° to 30° and a web thickness of 5% to 40%. The drilling simulation could accurately estimate the maximum bone temperature elevation for various surgical drill bit point angles, web thickness and helix angles. Looking into the future, this work will lead to the research and redesign of the optimum surgical drill bit to minimize thermal insult during bone-drilling surgeries.

Vibration Drilling the 0Cr18Ni9Ti Stainless Steel Micro-Hole

2012 ◽  
Vol 217-219 ◽  
pp. 1592-1595 ◽  
Author(s):  
Peng Zhang ◽  
Chang Hong Mei ◽  
Xing Yu Guo
Keyword(s):  
Stainless Steel ◽  
Hole Drilling ◽  
Drilling Process ◽  
Drill Bit ◽  
Drilling Force ◽  
Process Mechanism ◽  
Micro Hole ◽  
Vibration Drilling ◽  
Hole Machining

Austenite 0Cr18Ni9Ti stainless steel is one of difficult-to-cut materials. It has poor dilling process, especially for micro-hole machining. The main reasons are the tiny drill, poor rigidity, easy to deviation. Moreover, the chip is difficult to discharge, so the drilling force is increased and the drill bit is easy to break, or even it is impossible for micro-hole drilling. In this paper, the vibration drilling process is adopted. The vibration drilling 0Cr18Ni9Ti stainless steel micro-hole process mechanism is researched. The stainless steel micro-hole drilling experiments are conducted. The results show that the vibration drilling can be a better solution for 0Cr18Ni9Ti stainless steel micro-hole processing.

Torsional Vibrations and Nonlinear Dynamic Characteristics of Drill Strings and Stick-Slip Reduction Mechanism

2019 ◽  
Vol 14 (8) ◽  
Author(s):  
Jialin Tian ◽  
Genyin Li ◽  
Liming Dai ◽  
Lin Yang ◽  
Hongzhi He ◽  
...  
Keyword(s):  
Torsional Vibration ◽  
Nonlinear Dynamic ◽  
Drill String ◽  
Drilling Process ◽  
Drill Bit ◽  
Torsional Vibrations ◽  
Reduction Mechanism ◽  
Nonlinear Dynamic Model ◽  
Stick Slip ◽  
Research Results

Torsional stick–slip vibrations easily occur when the drill bit encounters a hard or a hard-soft staggered formation during drilling process. Moreover, serious stick–slip vibrations of the drill string is the main factor leading to low drilling efficiency or even causing the downhole tools failure. Therefore, establishing the stick–slip theoretical model, which is more consistent with the actual field conditions, is the key point for new drilling technology. Based on this, a new torsional vibration tool is proposed in this paper, then the multidegree-of-freedom torsional vibrations model and nonlinear dynamic model of the drill string are established. Combined with the actual working conditions in the drilling process, the stick–slip reduction mechanism of the drill string is studied. The research results show that the higher rotational speed of the top drive, smaller viscous damping of the drill bit, and smaller WOB (weight on bit) will prevent the stick–slip vibration to happen. Moreover, the new torsional vibration tool has excellent stick–slip reduction effect. The research results and the model established in this paper can provide important references for reducing the stick–slip vibrations of the drill string and improving the rock-breaking efficiency.

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