Research on Mechanism of Rock Breaking and Speed Increase in Cutting with Abnormal PDC Cutter

doi:10.3969/j.issn.1004-132X.2022.17.015

Abstract

Abstract: A tri-dimensional finite element numerical simulation model for cutting heterogeneous granites with specially-shaped cutter and full-sized bits was established based on the indoor cutting experiments. The values of tangential force， normal force， rock debris and MSE in the cutting processes of heterogeneous rocks with 12 kinds of PDC cutters were discussed， and the influences of cutter shape on rock-breaking efficiency of full-sized bits were also studied. The research results show that the tangential force of the conical cutter is the smallest， the MSE is the highest， and the footage of the corresponding conical cutter bits is also the smallest. Among all the cutters， the normal force and tangential force of the tri-planar cutters are the largest， while the MSE hyperboloid-shaped cutters is the smallest. Bits with saddle-shaped cutter， hyperboloid-shaped cutter or axe-shaped cutter which are easier to penetrate into rocks are able to have larger footage.

Key words: granite, polycrystalline diamond compact（PDC） cutter, drill bit, cutting force, mechanical specific energy（MSE）

摘要： 在室内切削实验基础上基于有限元二次开发建立了异形齿切削及全钻头破碎非均质花岗岩的三维数值仿真模型，研究了12种形状聚晶金刚石复合片（PDC）齿切削非均质岩石过程中的切向力、法向力、岩屑、破岩比功，并研究了齿形对全尺寸钻头破岩效率的影响。研究结果表明：锥形齿的切向力最小，破岩比功最高，对应的锥形齿钻头的进尺也最小；三平面齿的法向力和切向力均为最大；破岩比功最低的齿为双曲面齿；进尺最大的全钻头齿形为更易吃入岩石的鞍形齿、双曲面齿以及斧形齿。

关键词: 花岗岩, PDC齿, 全钻头, 切削力, 破岩比功

CLC Number:

TE242

LIU Weiji, YANG Feilong, ZHU Xiaohua, LUO Yunxu, HELing. Research on Mechanism of Rock Breaking and Speed Increase in Cutting with Abnormal PDC Cutter[J]. China Mechanical Engineering, 2022, 33(17): 2133-2141.

刘伟吉, 阳飞龙, 祝效华, 罗云旭, 何灵. 异形PDC齿切削破岩提速机理研究[J]. 中国机械工程, 2022, 33(17): 2133-2141.

References

［1］LIU Weiji， ZHU Xiaohua， ZHOU Yunlai， et al. The Rock Failure Behavior Analysis in Rock Cutting Using Finite Element Analysis［C］∥International Conference on Numerical Modelling in Engineering. Singapore， 2019：143-149.
［2］祝效华，刘伟吉. 单齿高频扭转冲击切削的破岩及提速机理［J］. 石油学报， 2017， 38（5）：578-586.
ZHU Xiaohua， LIU Weiji. The Rock Breaking and ROP Rising Mechanism for Single-cutter High-frequency Torsional Impact Cutting［J］. Acta Petrolei Sinica， 2017， 38（5）：578-586.
［3］XIONG Chao， HUANG Zhongwei， YANG Ruiyue， et al. Comparative Analysis Cutting Characteristics of Stinger PDC Cutter and Conventional PDC Cutter［J］. Journal of Petroleum Science and Engineering， 2020， 189：106792
［4］DAI Xianwei， HUANG Zhongwei， SHI Huaizhong， et al. Rock Failure Analysis Based on the Cutting Force in the Single PDC Cutter Tests［J］. Journal of Petroleum Science and Engineering， 2020， 194：107339.
［5］左汝强. 国际油气井钻头进展概述（三）——PDC钻头发展进程及当今态势（上）［J］. 探矿工程（岩土钻掘工程）， 2016， 43（3）：1-8.
ZUO Ruqiang. International Advancement of Drilling Bits for Oil and Gas Well（3）—PDC Bits Progress and Present Trend（Ⅰ）［J］. Exploration Engineering（Rock & Soil Drilling and Tunneling）， 2016， 43（3）：1-8.
［6］李相勇. 复合冲击钻井工具在深部难钻地层的应用［J］. 西部探矿工程， 2019， 31（8）：70-72.
LI Xiangyong. Application of Compound Percussion Drilling Tool in Deep Difficult-to-drill Stratum［J］. West-China Exploration Engineering， 2019， 31（8）：70-72.
［7］张辉，蔡志翔，姜敞，等. 深部岩石高效破碎方法研究［J］. 西部探矿工程， 2018， 30（9）：75-79.
ZHANG Hui， CAI Zhixiang， JIANG Chang， et al. Research on High Efficient Fragmentation Method of Deep Rock［J］. West-China Exploration Engineering， 2018， 30（9）：75-79.
［8］吴泽兵，吕澜涛，王勇勇，等. 牙轮—PDC混合钻头的破岩特性及温度场变化［J］. 天然气工业， 2020， 40（3）：99-106.
WU Zebing， LYU Lantao， WANG Yongyong， et al. Rock-breaking Characteristics and Temperature Field Change of Cone-PDC Hybrid Bits［J］. Natural Gas Industry， 2020， 40（3）：99-106.
［9］林兆虎. 新型非平面PDC切削齿的研究与设计［D］. 成都：西南石油大学， 2019.
LIN Zhaohu. Research and Design of New Non-planar PDC Cutter［D］. Chengdu：Southwest Petroleum University， 2019.
［10］ZIJSLING D H. Single Cutter Testing—a Key for PDC Bit Development［C］∥SPE Offshore Europe. Aberdeen， 1987：16529-MS.
［11］APPL F C， WILSON C C， LAKSHMAN I. Measurement of Forces， Temperatures， and Wear of PDC Cutters in Rock Cutting［J］. Wear， 1993， 169（1）：9-24.
［12］CHENG Zhen， LI Gensheng， HUANG Zhongwei， et al. Analytical Modelling of Rock Cutting Force and Failure Surface in Linear Cutting Test by Single PDC Cutter［J］. Journal of Petroleum Science and Engineering， 2019， 177：306-316.
［13］AMRI M， PELFRENE G， GERBAUD L， et al. Experimental Investigations of Rate Effects on Drilling Forces under Bottomhole Pressure［J］. Journal of Petroleum Science and Engineering， 2016， 147：585-592.
［14］KAITKAY P， LEI S. Experimental Study of Rock Cutting under External Hydrostatic Pressure［J］. Journal of Materials Processing Technology， 2005， 159（2）：206-213.
［15］RAFATIAN N， MISKA S Z， LEDGERWOOD L W， et al. Experimental Study of MSE of a Single PDC Cutter Interacting with Rock under Simulated Pressurized Conditions［C］∥SPE/IADC Drilling Conference and Exhibition. Amsterdam， 2009.
［16］RICHARD T， DAGRAIN F， POYOL E， et al， Rock Strength Determination from Scratch Tests［J］. Engineering Geology， 2012， 147/148：91-100.
［17］HARELAND G， YAN W， NYGAARD R， et al. Cutting Efficiency of a Single PDC Cutter on Hard Rock［J］. Journal of Canadian Petroleum Technology， 2007， 48（6）：60-65.
［18］TEALE R. The Concept of Specific Energy in Rock Drilling［J］. International Journal of Rock Mechanics and Mining Sciences & Geomechanics Abstracts， 1965， 2（1）：57-73.
［19］ZHOU Yaneng， LIN J S. Modeling the Ductile—Brittle Failure Mode Transition in Rock Cutting［J］. Engineering Fracture Mechanics， 2014， 127：135-147.
［20］AKBARI B， MISKA S， MENGJIAO Y， et al. Effect of Rock Pore Pressure on Mechanical Specific Energy of Rock Cutting Using Single PDC Cutter［C］∥47th U. S. Rock Mechanics/Geomechanics Symposium. San Francisco， 2013.
［21］祝效华，李海. PDC切削齿破岩效率数值模拟研究［J］. 应用基础与工程科学学报， 2015， 23（1）：182-191.
ZHU Xiaohua， LI Hai. Numerical Simulation on Mechanical Special Energy of PDC Cutter Rock-cutting［J］. Journal of Basic Science and Engineering， 2015， 23（1）：182-191.
［22］MAZEN A Z， RAHMANIAN N， MUJTABA I M， et al， Effective Mechanical Specific Energy：a New Approach for Evaluating PDC Bit Performance and Cutters Wear［J］. Journal of Petroleum Science and Engineering， 2021， 196， 108030.
［23］汪海阁，葛云华，石林. 深井超深井钻完井技术现状、挑战和“十三五”发展方向［J］. 天然气工业， 2017， 37（4）：1-8.
WANG Haige， GE Yunhua， SHI Lin. Technologies in Deep and Ultra-deep Well Drilling：Present Status， Challenges and Future Trend in the 13th Five-year Plan Period［J］. Natural Gas Industry， 2017， 37（4）：1-8.
［24］邹德永，郭玉龙，赵建，等. 锥形PDC单齿破岩实验研究［J］. 石油钻探技术， 2015， 43（1）：122-125.
ZOU Deyong， GUO Yulong， ZHAO Jian， et al. Experimental Study on Rock Breaking of Conical PDC Cutter［J］. Petroleum Drilling Techniques， 2015， 43（1）：122-125.
［25］石林，汪海阁，纪国栋. 中石油钻井工程技术现状、挑战及发展趋势［J］. 天然气工业， 2013， 33（10）：1-10.
SHI Lin， WANG Haige， JI Guodong. Current Situation， Challenges and Developing Trend of CNPC′s Oil & Gas Drilling［J］. Natural Gas Industry， 2013， 33（10）：1-10.
［26］夏宏南，王克雄，翟应虎，等. 围压条件下PDC钻头不同齿形的破岩实验研究［J］. 江汉石油学院学报， 1997（4）：50-52.
XIA Hongnan， WANG Kexiong， ZHAI Yinghu， et al. Experimental Research of PDC Cutter Shapes on Breaking Rock Efficiency under Various Confining Pressures［J］. Journal of Jianghan Petroleum Institute， 1997（4）：50-52.
［27］WISE J L. Geometry and Material Choices Govern Hard-rock Drilling Performance of PDC Drag Cutters［C］∥The 40th U. S. Symposium on Rock Mechanics（USRMS）. Anchorage， 2005.
［28］王滨，邹德永，林森，等. 锥形PDC齿耐磨性能实验研究［J］. 石油机械， 2015， 43（7）：23-26.
WANG Bin， ZOU Deyong， LIN Seng， et al. Wear Resistance Test of Conical PDC Cutter［J］. China Petroleum Machinery， 2015， 43（7）：23-26.
［29］谢晗，况雨春，秦超. 非平面PDC切削齿破岩有限元仿真及实验［J］. 石油钻探技术， 2019， 47（5）：69-73.
XIE Han， KUANG Yuchun， QIN Chao. The Finite Element Simulation and Test of Rock Breaking by Non-planar PDC Cutting Cutter［J］. Petroleum Drilling Techniques， 2019， 47（5）：69-73.
［30］CRANE D， ZHANG Y， DOUGLAS C， et al. Innovative PDC Cutter with Elongated Ridge Combines Shear and Crush Action to Improve PDC Bit Performance［C］∥SPE Middle East Oil & Gas Show and Conference. Manama， 2017.
［31］STOCKEY D， DIGIOVANNI A， FUSELIER D， et al. Innovative Non-planar Face PDC Cutters Demonstrate 21% Drilling Efficiency Improvement in Interbedded Shales and Sand［C］∥IADC/SPE Drilling Conference and Exhibition. Fort Worth， 2014.
［32］LIU Weiji， QIAN Xudong， LI Tao， et al. Investigation of the Tool-rock Interaction Using Drucker-Prager Failure Criterion［J］. Journal of Petroleum Science and Engineering， 2019， 173：269-278.

[1]	GAO Yuan, WU Qiwei, SONG Yang, QU Da. Design of Smart Tool Holders and Systems Based on Multi-sensor Information Fusion [J]. China Mechanical Engineering, 2026, 37(1): 184-191.
[2]	QI Shutao, LI Jiaqi, ZHENG Shucai, XU Jinting, SUN Yuwen. Instantaneous Milling Force Modeling and Coefficient Calibration Method of Variable Helical Circular-arc End Mills with Unequal Rake Angle [J]. China Mechanical Engineering, 2025, 36(04): 681-687,696.
[3]	WANG Haiyan, ZHOU Zhitong, WU YeFU Qilin. Modeling of Cutting Force in Helical Milling of Titanium Alloys Based on Oblique Cutting Theory [J]. China Mechanical Engineering, 2023, 34(02): 142-147.
[4]	WU Fenghe, ZHANG Ning, LI Yuanxiang, ZHANG Huilong, GUO Baosu, . Compressed Sensing Method for Cutting Force Signals Based on Improved Gauss Random Measurement Matrix [J]. China Mechanical Engineering, 2021, 32(18): 2231-2238.
[5]	ZHUANG Kejia, HU Cheng, DAI Xing, PU Donglin, DING Han. Prediction of Cutting Forces for Chamfered Inserts Based on Modified Slip-line Field Model#br# [J]. China Mechanical Engineering, 2021, 32(08): 890-906.
[6]	SHANG Peng, HUANG Sishuo, LIU Xiaopeng, YANG Zhuang, LIU Teng, ZHANG Jianjun. Modeling and Experimental Study on Cutting Forces of 2D Vibration Assisted Micro-milling [J]. China Mechanical Engineering, 2021, 32(06): 648-657，665.
[7]	CAI Anjiang;LIU Libo;LIU Lei;LI Wenbo. Influences of Cutting Parameters on Shaving Cutting Forces and Tooth Profile Concave Errors [J]. China Mechanical Engineering, 2020, 31(06): 655-661.
[8]	LI Qin;FU Wentao;HUANG Zhiqiang;MA Yachao;XIE Dou. Rock Breaking Characteristics of a Single Cone-PDC Combined Drill Bit in Hard Formation [J]. China Mechanical Engineering, 2019, 30(22): 2683-2690.
[9]	MENG Zhen1,2;CUI Zhi1;NI Jing1,2;YANG Yongfeng1,2. Effects of Surfactant on Performances of Atomized Nano Cutting Fluid after Ultrasonic Dispersion in Abrasive Cutting-grinding [J]. China Mechanical Engineering, 2019, 30(07): 852-857.
[10]	DU Maohua1;WANG Junhua2;ZHANG Jianfei1;WANG Shensong1. Robust Design Optimization Analysis of Experimental Results in High Speed Milling of an Alloy Cast Iron [J]. China Mechanical Engineering, 2019, 30(05): 554-559.
[11]	WANG Min. Cutting Parameter Optimization and Cutting Force Prediction for Fe-based Amorphous Alloy Spray-fused Coatings [J]. China Mechanical Engineering, 2017, 28(21): 2627-2631,2638.
[12]	ZHANG Quanbiao;WANG Guofeng;SONG Qingyue;WU Lirui;YANG Xinghuan. Multi-axis Linkage Servo System Simulation Considering Cutting Force Interferences [J]. China Mechanical Engineering, 2017, 28(14): 1718-1723.
[13]	Zhou Hongming, Zhang Heng, Zhang Xianglei, Peng Jiaojiao, Zhang Xiangxiang. Drill Bit Cold Heading Parametric Modeling and Forming Process Optimization [J]. China Mechanical Engineering, 2016, 27(21): 2962-2966.
[14]	Huan Haixiang, , Xu Jiuhua, Su Honghua, Fu Yucan, Liang Xinghui, Ge Yingfei. Study on Tool Wear Characteristics during Turning Titanium Matrix Composite Using PCD and Carbide Tools [J]. China Mechanical Engineering, 2016, 27(14): 1877-1883.
[15]	Liu Can, Wu Jingquan, Liu Huanlao, Tan Guangyu. Study on Variation Regulation of Cutting Forces in Multi-edge Cutting with Flat End Mills [J]. China Mechanical Engineering, 2016, 27(10): 1352-1357.