Laboratory Comparison of SMART*CUT Picks With WC Picks

2014 ◽  
Vol 1017 ◽  
pp. 323-328 ◽  
Author(s):  
W. Shao ◽  
Xing Sheng Li ◽  
Yong Sun ◽  
Han Huang
Keyword(s):  
Hard Rock ◽  
Cutting Tools ◽  
Infrared Camera ◽  
Polycrystalline Diamond ◽  
Rock Excavation ◽  
Research Organisation ◽  
Recorded Data ◽  
Bonding Technology ◽  
Cutter Forces ◽  
Polycrystalline Diamond Compact

Application of polycrystalline diamond compact (PDC) based cutting tools for hard rock excavation in mining and construction industries has increased significantly in recent years due to their super hardness, superb thermal conductivity and long life durability. Super Material Abrasive Resistant Tool (SMART*CUT) technology has been developed by CSIRO (Commonwealth Scientific and Industrial Research Organisation) in the last 15 years, which includes the replacement of tungsten carbide (WC) tips of the conventional picks with thermally stable diamond composite (TSDC) tips, attachment of the TSDC tips to steel tool bodies with CSIRO’s worldwide patented bonding technology. The wear characteristics of TSDC cutting elements have been investigated previously. In this paper, the preliminary results of cutter forces and resultant angle of SMART*CUT picks were compared with that of traditional WC picks. A tri-axial force dynamometer and a data acquisition system were used to measure the cutter forces. Besides, the cutting area temperature during cutting process was continuously measured by a FLIR SC7600M thermal infrared camera and the recorded data were processed by Altair Software.

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.

Assured Stability of Drillstrings Equipped With Polycrystalline Diamond Compact (PDC) Bits

2003 ◽  
Author(s):  
M. A. Elsayed
Keyword(s):  
Stability Analysis ◽  
Geothermal Energy ◽  
Hard Rock ◽  
Rock Type ◽  
Polycrystalline Diamond ◽  
Deep Wells ◽  
Drilling Parameters ◽  
Pipe Joints ◽  
Polycrystalline Diamond Compact ◽  
Oil Gas

Drillstrings equipped with PDC bits are commonly used to drill for oil, gas and geothermal energy. Drillstring instability — defined as the tendency of self-excited vibrations (chatter) to grow with time — causes failure of PDC bits as well as pipe joints. This problem becomes particularly severe in deep wells and hard rock. Much work has been performed in predicting stability. Bit and drillstring geometry as well as rock type affect stability. In this paper, we propose a scheme to assure stability for a given drillstring regardless of bit geometry, utilizing the desired drilling parameters. The effect of bit geometry and rock type in the classic stability analysis are replaced by the drilling parameters, namely: weight-ob-bit (WOB), rate of penetration (ROP) and speed (RPM). Experimental data obtained at Sandia National Labs, Albuquerque, N.M. is used to verify the assured stability equation. This approach is much simpler that classic stability analysis.

Development of Hard Rock Cutting Tool with Advanced Diamond Composites

2013 ◽  
Vol 690-693 ◽  
pp. 1831-1835 ◽  
Author(s):  
X.S. Li ◽  
Yong Sun
Keyword(s):  
Cutting Tool ◽  
Hard Rock ◽  
Tool Material ◽  
Rock Cutting ◽  
Rock Excavation ◽  
Diamond Composite ◽  
Normal Forces ◽  
Bonding Technology ◽  
Bottle Neck ◽  
Better Than

The modern mechanical excavation machines have enough power for cutting hard rock. The bottle neck which limits the use of machines for hard rock excavation is cutting tool. To cut hard and abrasive rock, CSIRO has been developing Super Material Abrasive Resistant Tools (SMART*CUT). SMART*CUT technology replaces the tungsten carbide (WC) tip of conventional pick with thermally stable diamond composite (TSDC) and attaches the TSDC tip to steel tool body with CSIRO worldwide patented bonding technology. This paper compares its performance with conventional WC tipped tools by a series of hard rock cutting tests. The cutting and normal forces acting on the tools were measured during these tests. The tests shown that the cutting performance of SMART*CUT pick was significantly better than that of WC pick. The testing results indicate that TSDC can be applied as an effective cutting tool material for cutting hard and abrasive rocks.

Linear Rock Cutting with SMART*CUT Picks

2013 ◽  
Vol 477-478 ◽  
pp. 1378-1384 ◽  
Author(s):  
Wen Shao ◽  
Xing Sheng Li ◽  
Yong Sun ◽  
Han Huang
Keyword(s):  
Hard Rock ◽  
Normal Force ◽  
Cutting Tools ◽  
Rock Cutting ◽  
Attack Angle ◽  
High Wear Resistance ◽  
Depth Of Cut ◽  
Good Thermal Stability ◽  
Cutter Forces ◽  
Selection Of

The short life due to heavy wear is a bottleneck that limits the usage of mechanical excavators for hard rock cutting. Thermally stable diamond composite (TSDC) tipped cutting tools have the main advantages of good thermal stability, high wear resistance and ability to mine harder deposit compared to the conventional tungsten carbide (WC) tipped cutting tools. Super Material Abrasive Resistant Tool (SMART*CUT) based on TSDC tip has been developed by CSIRO to improve the effectiveness of cutting tools when dealing with hard deposit in mining and civil industries. In this study, the effects of attack angle and depth of cut on the cutting performance of SMART*CUT picks in different cutting orientations were investigated. A tri-axial dynamometer and a data acquisition system were used to measure the cutter forces. Normal force, cutting force and resultant angle were correlated with depth of cut and attack angle. Cutting performances were compared in different cutting orientations. The results would be beneficial to the selection of mechanical excavator motor and the optimization of cutting drum design to some extent.

Analysis of Coupling Between Axial and Torsional Vibration in a Compliant Model of a Drillstring Equipped With a PDC Bit

2002 ◽  
Author(s):  
M. A. Elsayed ◽  
David W. Raymond
Keyword(s):  
Hard Rock ◽  
Polycrystalline Diamond ◽  
Operating Conditions ◽  
Axial Vibration ◽  
Rock Drilling ◽  
Stick Slip ◽  
Vibration Data ◽  
Pdc Bit ◽  
Show Evidence ◽  
Polycrystalline Diamond Compact

In this paper, we discuss results of rock drilling tests at Sandia National Laboratories’ Hard Rock Drilling Facility (HRDF). The HRDF incorporates a drillstring with axial and torsional compliance and is equipped with a coring bit having PDC (Polycrystalline Diamond Compact) cutters. We measure and analyze chatter and show evidence of stick-slip as well as coupling between axial and torsional vibrations. We show the coupling signature in axial vibration data in the form of side bands indicating frequency modulation at the torsional natural frequency. The influence of operating conditions on the bit response is shown.

scholarly journals Bionic design and test of polycrystalline diamond compact bit for hard rock drilling in coal mine

2020 ◽  
Vol 12 (5) ◽  
pp. 168781402092318
Author(s):  
Chuanliu Wang
Keyword(s):  
Service Life ◽  
Coal Mine ◽  
Hard Rock ◽  
Polycrystalline Diamond ◽  
Research Direction ◽  
Future Research ◽  
Test Results ◽  
Bionic Design ◽  
Rock Drilling ◽  
Polycrystalline Diamond Compact

For hard rock drilling in coal mine, the drilling efficiency and service life of polycrystalline diamond compact bit are very low. To overcome these shortcomings, the bionic technology is applied to the design and processing of polycrystalline diamond compact bit. The bit body and polycrystalline diamond compact cutter are designed as bionic structures, and the test of the bionic polycrystalline diamond compact bit is carried out. Test results show that, when drilling in fine sandstone with hardness greater than 9, the performance of the bionic polycrystalline diamond compact bit is significantly improved. Comparing with the Φ113-mm concave polycrystalline diamond compact bit, the service life and drilling efficiency of the A-type bionic polycrystalline diamond compact bit increase by 54% and 230%, respectively, the service life and drilling efficiency of the B-type bionic polycrystalline diamond compact bit increase by 345% and 204%, respectively, which show that the bionic design of polycrystalline diamond compact bit can provide a new research idea for hard rock drilling in coal mine. Also the test results indicate that, when processing the bionic polycrystalline diamond compact cutter, the linear cutting process will cause thermal damage to the diamond layer of polycrystalline diamond compact cutter, while the cold grinding process shows higher comprehensive performance, therefore the one-time synthesis of bionic polycrystalline diamond compact cutter is the future research direction.

Development of New PDC Bits for Drilling of Geothermal Wells—Part 1: Laboratory Testing

1992 ◽  
Vol 114 (4) ◽  
pp. 323-331 ◽  
Author(s):  
H. Karasawa ◽  
S. Misawa
Keyword(s):  
Hard Rock ◽  
Rock Type ◽  
Penetration Rate ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Rake Angle ◽  
Well Drilling ◽  
Pdc Bit ◽  
Geothermal Wells ◽  
Polycrystalline Diamond Compact

Rock cutting, drilling and durability tests were conducted in order to obtain data to design polycrystalline diamond compact (PDC) bits for geothermal well drilling. Both conventional and new PDC bits with different rake angles were tested. The rock cutting tests revealed that cutting forces were minimized at −10 deg rake angle independent of rock type. In drilling and durability tests, a bit with backrake and siderake angles of −10 or −15 deg showed better performance concerning the penetration rate and the cutter strength. The new PDC bit exhibited better performance as compared to the conventional one, especially in hard rock drilling. Furthermore, a new PDC core bit (98.4 mm o. d., 66 mm i. d.) with eight cutters could be successfully applied to granite drilling equally as well as a bit with twelve cutters.

Development of New PDC Bits for Drilling of Geothermal Wells—Part 2: Field Testing

1992 ◽  
Vol 114 (4) ◽  
pp. 332-338
Author(s):  
S. Misawa ◽  
H. Karasawa
Keyword(s):  
Hard Rock ◽  
Field Tests ◽  
Polycrystalline Diamond ◽  
Field Testing ◽  
Hot Dry Rock ◽  
Rock Formations ◽  
Geothermal Wells ◽  
Project Site ◽  
Polycrystalline Diamond Compact

In order to develop polycrystalline diamond compact (PDC) bits of about 8-1/2 in. in diameter which are able to drill geothermal wells, we have conducted the investigation with respect to the structure of a PDC cutter and rake angles, etc., by means of fundamental laboratory and field tests. New PDC core bits of 8-15/32 in. diameter were designed and manufactured based on the results of these tests. Then, field tests using them were carried out in geothermal wells at Hijiori in Yamagata prefecture, Hot Dry Rock project site in Japan, on September 1989 and October 1990. It became clear that the new PDC core bit can be sufficiently applied to the drilling of heterogeneous hot-hard rock formations from the tests.

Micro-Raman Stress Investigation of Polycrystalline Diamond Compact (PDC)

2009 ◽  
Vol 76-78 ◽  
pp. 690-695 ◽  
Author(s):  
Guo Ping Xu ◽  
Gen Xu ◽  
Zhi Min Yin ◽  
Rong Chao Jiang
Keyword(s):  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Diamond Surface ◽  
Electric Discharge Machining ◽  
Diamond Layer ◽  
Micro Raman Spectroscopy ◽  
Vertical Distributions ◽  
Side Face ◽  
Main Factors ◽  
Polycrystalline Diamond Compact

The residual stresses on the top surface and side face of the diamond layer of PDC with 25.4mm in diameter and 3.2mm in thickness were measured using Micro-Raman Spectroscopy, thus the stresses and their radial and vertical distributions were obtained. To evaluate the magnitude of the thermal residual microstress in the diamond layer of PDC, the tungsten carbide substrate of PDC was cut by electric discharge machining (EDM), and several Raman measurements were performed on the top surface of the diamond layer. The results show that 1) the stresses in the central part of the diamond surface are compressive, the biggest stress is about 600 MPa, the magnitude of the stress decreases from the center to the edge of PDC, and at about 2mm near the edge of PDC, the stress becomes tensile; 2) the stresses on the side face of the diamond layer are tensile, the maximum is about 580 MPa near the interface. These tensile stresses are thought to be one of the main factors to cause delamination of PDC used for cutting tools; 3) the measured value of the microstress in the diamond layer is 62.5MPa.

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