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1
Wang, Zong Gang, Zhen Wei, and Lai Ju Han. "Microwave PDC Drill Bit." Advanced Materials Research 774-776 (September 2013): 1414–17. http://dx.doi.org/10.4028/www.scientific.net/amr.774-776.1414.
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On the rotary drilling system, the technologies for fracturing and cutting hard rock are mainly mechanical rock breaking methods by use of improving bottomhole water horse power and bit energy, and the working life and rock breaking efficiency have much room for improvement. Microwave crag broken is a thermal assisted rock breaking method which could melt rocks. Microwave assisted rock breaking method will not bring new impact, wear and tear, instead, the microwave pretreatment on the rock reduces the difficulty of breaking rock and prolongs the service life of the drill bit. Under the combined action of microwave heat and mechanical energy of PDC bit, the rock breaking efficiency is improved greatly, and the drilling cost is reduced significantly.
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Soegihardjo, Oegik, and Samuel Trinata. "Simulasi Perubahan Back Rake Angle Polycrystalline Diamond Carbide Drill Bit untuk Meminimalkan Keausan Pahat." Jurnal Teknik Mesin 17, no. 2 (October 8, 2020): 34–37. http://dx.doi.org/10.9744/jtm.17.2.34-37.
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The drilling process of an oil well uses a drill bit to drill a hole to drain crude oil from the bowels of the earth to the ground. Tool wear occurs in every cutting or drilling process that uses tool bits. A drill bit is the general term for the tool blade used in the drilling process. Two types of tool bits that are commonly used are roller cone and Polycrystalline Diamond Carbide drill bit or PDC. The case being study is the wear out of the PDC drill bit, that causing unplanned bit trip. This research was conducted as an effort to reduce the wear that occurs on the PDC drill bit. The aim of the research is to simulate the changes of the back rake angle, so that the impact of the back rake angle's changes on the wear of the drill bit could be investigated. The results of the simulations were compared with the tool wear data that occurred at one of the oil drilling locations.
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Jinping, Yu, Zou Deyong, Sun Yuanxiu, and Zhang Yin. "Simulation and Experimental Study of the Rock Breaking Mechanism of Personalized Polycrystalline Diamond Compact Bits." Journal of Engineering Science and Technology Review 13, no. 5 (2020): 122–31. http://dx.doi.org/10.25103/jestr.135.16.
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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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Ayop, Ahmad Zhafran, Ahmad Zafri Bahruddin, Belladonna Maulianda, Aruvin Prakasan, Shamammet Dovletov, Eziz Atdayev, Ahmad Majdi Abdul Rani, et al. "Numerical modeling on drilling fluid and cutter design effect on drilling bit cutter thermal wear and breakdown." Journal of Petroleum Exploration and Production Technology 10, no. 3 (October 11, 2019): 959–68. http://dx.doi.org/10.1007/s13202-019-00790-7.
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Abstract The unconventional reservoir geological complexity will reduce the drilling bit performance. The drill bit poor performance was the reduction in rate of penetration (ROP) due to bit balling and worn cutter and downhole vibrations that led to polycrystalline diamond compact (PDC) cutter to break prematurely. These poor performances were caused by drilling the transitional formations (interbedded formations) that could create huge imbalance of forces, causing downhole vibration which led to PDC cutter breakage and thermal wear. These consequently caused worn cutter which lowered the ROP. This low performance required necessary improvements in drill bit cutter design. This research investigates thermal–mechanical wear of three specific PDC cutters: standard chamfered, ax, and stinger on the application of heat flux and cooling effect by different drilling fluids by using FEM. Based on simulation results, the best combination to be used was chamfered cutter geometry with OBM or stinger cutter geometry with SBM. Modeling studies require experimental validation of the results.
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Kong, Chunyan, Rongjun Zhu, Derong Zhang, and Shuangshuang Li. "Research on kinematics analysis of spherical single-cone PDC compound bit and rock breaking simulation verification." Oil & Gas Science and Technology – Revue d’IFP Energies nouvelles 76 (2021): 52. http://dx.doi.org/10.2516/ogst/2021034.
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The single-cone bit has become the first choice for slim hole sidetracking and deep well drilling with its unique rock breaking method and high ROP (Rate Of Penetration), with its main failure mode being of early excessive wear of the cutting teeth. In order to improve the adaptability of single-cone bits to hard and highly abrasive formations, a spherical single-cone Polycrystalline Diamond Compact (PDC) compound bit is designed. According to the characteristics of the tooth profile, the way of tooth arrangement and the way of contact between the cutting teeth and the rock, the acceleration equation to the cutting teeth of the spherical single-cone PDC compound bit is established. The acceleration of the single-cone bit is verified by numerical simulation experiment of rock-breaking. The shaft inclination angle of the cone, the position and height of the PDC teeth, the radius of the PDC teeth, the lateral rotation angle and the front inclination angle on the acceleration are studied. The results show that as the shaft inclination angle increases, the bit transmission ratio gradually increases, and the harder the rock formation, the larger the transmission ratio of the single-cone bit; the shaft inclination angle and the position of the PDC tooth have a greater influence on the acceleration of the PDC tooth, and the radius, lateral rotation angle and front inclination angle of the PDC tooth have a small influence on the acceleration of the PDC tooth; rock properties have an impact on the acceleration of the cutting teeth, with the acceleration of the cutting teeth in hard rock formations being higher than that in soft rock formations; near the top of the cone, the absolute acceleration of the cutting teeth will fluctuate sharply and cause severe wear of the cutting teeth, so the tooth distribution in this area should be strengthened; on the premise that the bearing life of the single-cone bit is allowed, the value of the shaft inclination angle β can be approached to 70°. The relative error between the theoretical analysis results of the acceleration of the PDC cutter and the rock-breaking simulation experiment results is between −0.95% and −2.24%. This research lays a theoretical foundation for the dynamic research of spherical single-cone PDC compound bit.
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Hough, C. L., B. Das, and T. G. Rozgonyi. "Life Models for Small-Diameter Polycrystalline Diamond Compact Bits in Hard Abrasive Media." Journal of Energy Resources Technology 108, no. 4 (December 1, 1986): 310–14. http://dx.doi.org/10.1115/1.3231282.
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Mathematical models for bit life of polycrystalline diamond compact (PDC) drill bits were developed for drilling small holes in hard abrasive media. Based on the wear-out criterion of an average 0.060 in. (1.5 mm) flank wear land, bit life equations were formulated in three forms: bit life versus rotary speed and feed rate, bit life versus rotary speed and penetration rate, and wear rate versus cutting speed and cutter engagement area. The traditional linear-logarithmic model proved inadequate to describe bit life, whereas the quadratic-logarithmic model provided the best bit life prediction equation. Consequently, it would be possible to predict the optimum economical drilling conditions more accurately by employing a quadratic-logarithmic based bit life equation. The equation demonstrated the ability to predict the bit life precisely under different modes of wear.
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Abdul-Rani, A. M., M. Zamri Ismail, M. Ariff Zaky, M. Hariz M. Noor, Y. Y. Zhun, K. Ganesan, T. V. V. L. N. Rao, Subhash Kamal, and Turnad Lenggo Ginta. "Improving Rate of Penetration for PDC Drill Bit Using Reverse Engineering." Applied Mechanics and Materials 607 (July 2014): 153–60. http://dx.doi.org/10.4028/www.scientific.net/amm.607.153.
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In petroleum industry, drilling is one of the most important aspects due to its economics. Reduction in drilling time is desired to minimize operations cost. This work focus on Polycrystalline Diamond Compact (PDC) drill bit which is categorized as a fixed cutter drilling bit. Problem such as wear and tear of PDC cutter are some of the main factors in drilling process failure affecting the rate of penetration (RoP). Thus, an intensive study in drill bit design could potentially save costs if the drill bit efficiency can be improved. The objective of this research is to improve the PDC cutter design and analyse design improvement in relation to the rate of penetration using reverse engineering (RE) approach. RE method is capable of resolving unavailable drill bit blueprint from the manufacturer due to propriety and confidential. RE non-contact data acquisition device, 3D laser scanner will be used to obtain cloud data of the existing worn drill bit. Computer Aided Design (CAD) software is used to convert cloud data of the PDC drill bit into 3D CAD model. Optimization of PDC Drill bit is focused on feature design such as back rake angle, side rake angle and number of cutters. CAE software is used to analyse the effect of the design feature modification to rate of penetration. Results show rate of penetration increases as the angle of both rake angle and number of cutter decreases.
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Tretyak, A. A., K. A. Borisov, and A. N. Grossu. "Method of Calculating the Wear, ROP and PDC Bit Operating Time." IOP Conference Series: Earth and Environmental Science 272 (June 21, 2019): 022214. http://dx.doi.org/10.1088/1755-1315/272/2/022214.
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Glowka, D. A., and C. M. Stone. "Thermal Response of Polycrystalline Diamond Compact Cutters Under Simulated Downhole Conditions." Society of Petroleum Engineers Journal 25, no. 02 (April 1, 1985): 143–56. http://dx.doi.org/10.2118/11947-pa.
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Abstract An analytical method is developed to predict temperatures in polycrystalline diamond compact (PDC) drag cutters under steady-state and transient downhole conditions. The method is used to determine mean wearflat temperatures for cutters under conditions used in previous experiments to measure cutter wear. A correlation between wearflat temperatures and cutter wear rates is demonstrated, and it is shown that, for the particular rock type tested, cutter wear rates increase significantly above 350 degrees C [662 degrees F]. The concept of a critical weight on bit, above which wearflat temperatures exceed this value, is introduced. The effects of several parameters on the critical WOB are examined. These include cutter thermal conductivity, diamond layer thickness, rock properties. convective cooling, bit balling, and transient events such as bit bounce. Preliminary results of thermal stress modeling show that Preliminary results of thermal stress modeling show that plastic yielding of the cutter structure can occur under plastic yielding of the cutter structure can occur under certain downhole conditions. Introduction Drill bits using PDC drag cutters have been used for the past few years with considerable success in the oil and past few years with considerable success in the oil and gas drilling industry. Such bits have been shown to be quite sensitive, however, to formation characteristics and operating conditions, and the economic success of a particular bit run is highly dependent on identifying particular bit run is highly dependent on identifying appropriate drilling intervals and operating the bit within its limits. Our interest in PDC bit technology has been in determining the drilling potential of these bits in the more severe environments associated with geothermal resources. This paper addresses the thermal limitations of PDC bits in such environments and investigates the effects of design and operating parameters on these limitations. The work reported in this paper is an extension of work reported earlier. More generalized boundary conditions are used for the finite element thermal modeling of single PDC cutters. The results are used to demonstrate the PDC cutters. The results are used to demonstrate the apparent adverse effect of operating temperature on cutter wear rates. A more restrictive safe operating limit of 350 degrees C [662 degrees F] is proposed, rather than the 750 degrees C [1,382 degrees F] limit assumed in the earlier work. Cutter Temperature Theory and Analysis The thermal phenomena considered in this analysis are frictional heating and convective cooling of PDC cutters under downhole drilling conditions. Fig. 1 is a graphical representation of this process. Because of the relative motion between the cutter and the rock, frictional heat is generated at the interface. The total quantity of frictional heat per unit wearflat area per unit time is (1) Because of the intimate contact between the cutter and the rock, this heat flux is divided between the cutter, Q1, and the rock, Qf, according to the value of the energy partitioning fraction a: partitioning fraction a: (2) and (3) The value of a depends on the relative thermal resistances of the cutter and the rock, which in turn depend on their thermal properties, convective cooling rates, cutting speed, and cutter geometry. A measure of the thermal resistance of the rock is obtained from the literature. Jaeger gives the solution for the mean temperature rise of the contact area between a sliding, square heat source and the surface of a semi-infinite slab as (4) where khf and af are thermal properties of the rock, L is the wearflat length parallel to the cutting direction, and v is the coning speed. Because of the intimate contact between the cutter and the rock, it may be assumed that (5) Combining Eqs. 2 through 5 and assuming that the wellbore has been cooled by the drilling fluid such that Tf = Tfl, the general result is (6) SPEJ p. 143
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Poletto, Flavio. "Energy balance of a drill-bit seismic source, part 2: Drill-bit versus conventional seismic sources." GEOPHYSICS 70, no. 2 (March 2005): T29—T44. http://dx.doi.org/10.1190/1.1897039.
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The radiation properties of a downhole drill-bit seismic source are related to the amplitude and frequency of the forces exerted by the working bit. The main vibration modes of roller-cone and polycrystalline diamond compact (PDC) bits are investigated under different drilling conditions. The analysis includes vibrations produced by teeth indention, multilobed patterns, bouncing with periodic and random effects, single-cutter forces, stick-slip and whirling effects, mud-pressure modulation forces, and bit wear. Drill-bit radiation properties are calculated using the results obtained in part 1 of this paper and are numerically compared to the radiation of conventional vertical seismic profiling (VSP) sources.
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Kuru, E., and A. K. Wojtanowicz. "A Compound Effect of Cutting Depth and Bit Dull on Cutters’ Temperature for Polycrystalline Diamond Compact Bits." Journal of Energy Resources Technology 115, no. 2 (June 1, 1993): 124–32. http://dx.doi.org/10.1115/1.2905979.
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This paper presents a simulation study to evaluate the combined effect of cutting depth (drilling rate) and wear (bit dull) on the thermal response of polycrystalline diamond compact (PDC) cutters under downhole drilling conditions. A new understanding of frictionally generated heat between rock and PDC cutter is introduced from the analysis of forces active on the wearflat and the cutting (leading) surfaces of a cutter. Then this new concept is used to predict PDC bit performance with the controlled temperature of its cutters. Previous concepts, largely based on the laboratory drilling tests (with low drilling rate and under atmospheric conditions), recognize only one source of heat—the wearflat surface. However, this study, using field data, shows that the heat generated at the cutting surface may significantly contribute to the total heat flux in the cutter. As a result, the distribution of temperature within the cutter is changed, which particularly affects the maximum value of temperature at the cutting edge. A simplified 2-D finite difference numerical code is used to quantify the difference in cutter wearflat temperatures calculated with and without the additional heat flux generated at the cutting surface. The numerical analysis reveals that neglecting the cutting surface effect results in underestimation of the actual wearflat temperature by 10 to 530 percent, depending upon bit dull and downhole hydraulics. Also demonstrated is the actual impact of these findings on field drilling practices. The example comparison is made by calculating the optimal-control procedures for PDC bit with and without the effect of cutting surface. In these procedures, wearflat temperature becomes a mathematical constraint which limits weight on bit and rotational speed. The comparison includes calculation of the maximum bit performance curves which represent maximum drilling rate attainable for a bit to drill a predetermined length of a borehole (footage). The curves show an up to 18 percent reduction of drilling rate when the new and more rigorous temperature limitation is used. In addition, the example calculations show that the actual temperature of the bit cutters can be 460°C (860°F), and exceeds by almost 30 percent its maximum acceptable value of 350°C (660°F). For practical applications, the study reveals that many field failures of PDC bits may have been caused by lack of understanding of operational limits imposed by heat considerations.
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Mazen, Ahmed Z., Nejat Rahmanian, Iqbal M. Mujtaba, and Ali Hassanpour. "Effective mechanical specific energy: A new approach for evaluating PDC bit performance and cutters wear." Journal of Petroleum Science and Engineering 196 (January 2021): 108030. http://dx.doi.org/10.1016/j.petrol.2020.108030.
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Mazen, Ahmed Z., Iqbal M. Mujtaba, Ali Hassanpour, and Nejat Rahmanian. "Mathematical modelling of performance and wear prediction of PDC drill bits: Impact of bit profile, bit hydraulic, and rock strength." Journal of Petroleum Science and Engineering 188 (May 2020): 106849. http://dx.doi.org/10.1016/j.petrol.2019.106849.
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Wang, Yong, Hongjian Ni, Yiliu (Paul) Tu, Ruihe Wang, Xueying Wang, Heng Zhang, Jiaxue Lyu, and Hongqiao Xie. "Experimental Study on Axial Impact Mitigating Stick-Slip Vibration with a PDC Bit." Shock and Vibration 2021 (February 5, 2021): 1–8. http://dx.doi.org/10.1155/2021/8897283.
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Stick-slip vibration reduces the drilling rate of penetration, causes early wear of bits, and threatens the safety of downhole tools. Therefore, it is necessary to study suppression methods of stick-slip vibration to achieve efficient and safe drilling. Field tests show that the use of downhole axial impactors is helpful to mitigate stick-slip vibration and improve rock-breaking efficiency. However, there are many deficiencies in the study of how axial impact load affects stick-slip vibration of a PDC bit. In this paper, based on the two-degrees-of-freedom spring-mass-damper model and similarity theory, a laboratory experiment device for suppressing stick-slip vibration of a PDC bit under axial impact load has been developed, and systematic experimental research has been carried out. The results show that the axial impact force can suppress the stick-slip vibration by reducing the amplitude of weight on bit and torque fluctuations and by increasing the main frequency of torque. The amplitude of impact force affects the choice of the optimal back-rake angle. The impact frequency is negatively correlated with the fluctuation amplitude of the rotary speed. When the impact frequency is greater than 100 Hz, the fluctuation amplitude of the rotary speed will not decrease.
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Agostini, Cristiano Eduardo, and Marcio Augusto Sampaio. "Probabilistic Neural Network with Bayesian-based, spectral torque imaging and Deep Convolutional Autoencoder for PDC bit wear monitoring." Journal of Petroleum Science and Engineering 193 (October 2020): 107434. http://dx.doi.org/10.1016/j.petrol.2020.107434.
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Wang, Wei, Jun Li, Gong Hui Liu, and Chun Qing Cha. "Research on Design of Polycrystalline Diamond Composite Pendulum Wear-Resistant Belt." Materials Science Forum 944 (January 2019): 999–1004. http://dx.doi.org/10.4028/www.scientific.net/msf.944.999.
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The torque impactor can effectively solve the stick-slip vibration of PDC bit in the deep formation, but the wear of the pendulum seriously restricted the service life of the impactor. In order to reduce the wear of the pendulum under complicated working conditions, the polycrystalline diamond composite material was used as the wear-resistant material to design the pendulum wear-resistant belt. Based on the analysis of the feasibility of using polycrystalline diamond as pendulum wear-resistant material, the finite element model of dynamic contact interaction between pendulum wear-resistant belt and impact cylinder was established, the influence of the arrangement of wear-resistant blocks on the stress of the contact area between the pendulum wear-resistant belt and the impact cylinder was studied. The results show: Polycrystalline diamond composite material has stronger wear resistance and better anti-friction performance than conventional wear-resistant materials, and can reduce the wear of the inner wall of the impact cylinder, which is feasible on the surface of the pendulum hammer. The use of the wear-resistant belt structure is beneficial to improve the variation of the shear stress of the area where the pendulum and the impact cylinder contact each other. The wear-resistant belt structure is beneficial to improve the shear stress variation amplitude of the pendulum and impact cylinder in contact with each other. When the wear-resistant block is arranged in a circular block staggered arrangement, the shear stress change amplitude of the interaction contact area is the largest, the triangular block staggered arrangement mode is second, and the trough block shape staggered arrangement is the smallest. The research results have important reference significance for the design and application of polycrystalline diamond composite pendulum wear-resistant belt.
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Abdul-Rani, A. M., Khairiyah Ibrahim, A. H. Ab Adzis, B. T. Maulianda, and M. N. Mat Asri. "Investigation on the effect of changing rotary speed and weight bit on PCD cutter wear." Journal of Petroleum Exploration and Production Technology 10, no. 3 (November 12, 2019): 1063–68. http://dx.doi.org/10.1007/s13202-019-00795-2.
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Abstract The research is to determine the optimum range of rotary speed and weight-on-bit value for interbedded formation to reduce PCD cutter wear rate. To simulate an interbedded formation, a combination of limestone as the soft formation and granite as the hard formation is selected. The research is conducted based on analysis of cutter-rock interaction model, wear model and simulation of PCD cutter using finite element analysis in ABAQUS software. The results show that the optimum range of weight on bit and rotary speed for limestone is between 1000 N, 21.4 RPM, and 4000 N, 85.6 RPM, while for granite it is between 1000 N, 21.4 RPM and 3000 N, 64.2 RPM.
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Shengliang, Zhang, Wang Changhao, Liu Qiang, and Li Shibin. "Abrasiveness evaluation of complex strata based on PDC special energy consumption." Journal of Petroleum Exploration and Production Technology, January 2, 2021. http://dx.doi.org/10.1007/s13202-020-01063-4.
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AbstractThe rock abrasiveness is determined with various methods, which results in no uniform standard formed. In order to predict the PDC bit wear and the abrasiveness of complex strata, the force analysis of the PDC broken rock was carried out, and the bit axial load and torque were obtained, respectively. Then, the calculation model of PDC special energy consumption is deduced. Combining the typical distribution patterns of different strata, the specific energy prediction model of complex strata is established. The wear coefficient of PDC is obtained by the relationship between the triaxial compressive strength of rock and the specific energy of rock breaking, and the grading coefficient and grading standard of abrasiveness of the composite formation are derived, which led to the grading coefficient and grading standard of complex strata abrasiveness. The field test of a well in the north of Songliao Basin verified the rationality and effectiveness of the abrasiveness grading standards and provided the basis for the selection and design of the bit.
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Mirani, Ankit A., and Robello Samuel. "Discrete Vibration Stability Analysis With Hydromechanical Specific Energy." Journal of Energy Resources Technology 140, no. 3 (October 4, 2017). http://dx.doi.org/10.1115/1.4037899.
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Drill-bit vibrations and bit wear have been identified as the two major causes for premature polycrystalline diamond-compact (PDC) bit failure and difficulty in accurately predicting PDC bit performance. The objective of this paper is to present a new approach to drilling optimization by developing an algorithm that defines and generates a constrained stable rotary speed (RPM)–weight-on-bit (WOB) working domain for a given system as opposed to the traditional RPM–WOB charts. The algorithm integrates the dynamic-stability model for bit vibrations with the bit-performance model for degraded bits. This study addresses the issues of dynamic-bit stability under torsional and lateral vibrations coupled with bit wear. The approach presented in this paper involves performing two separate analyses: vibration stability and bit-wear performance analysis. The optimum operating conditions are estimated at each depth of the drilling interval, taking into consideration the effect of bit wear and bit vibrations. Because the bit wears continuously while penetrating the rocks, discretization of depth is necessary for effective simulation. Discretization is done by dividing the drilling interval into subintervals of the desired length. Vibration-stability analysis and bit-wear performance analysis are preformed separately at every subinterval and then integrated over the discrete interval. For every subinterval, a WOB–RPM domain is determined within which the given system is dynamically stable (for vibrations), and the bit wear does not exceed the maximum allowable wear (MAW) for the section of the drilling interval selected. A unique concept to relate the fractional change in hydromechanical specific energy (HMSE) to the fractional change in bit wear has also been put forward that further constraints the WOB–RPM stable working domain. The new coupled vibration-stability chart, including the maximum rate of penetration (ROP), narrows down the conventional chart and provides different regions of operational stability. It has also been found that as the compressive strength of the rock increases, the bit-gauge friction factor also increases, which results in a compressed or reduced allowable working domain, both from the vibration-stability analysis and bit-performance analysis. Simple guidelines have been provided using the new stability domain chart to estimate the operating range for real-time optimization.
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Chen, Pengju, Stefan Miska, Mengjiao Yu, and Evren Ozbayoglu. "Modeling of Cutting Rock: From PDC Cutter to PDC Bit—Modeling of PDC Cutter." SPE Journal, February 1, 2021, 1–21. http://dx.doi.org/10.2118/205342-pa.
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Summary The main purpose of this paper is to present our polycrystalline diamond compact (PDC) cutter model and its verification. The PDC cutter model we developed is focused on a PDC cutter cutting a rock in 3D space. The model studies the forces between a cutter and a rock and applies the theory of poroelasticity to calculate the stress state of the rock during the cutting process. Once the stress state of the rock is obtained, the model can then predict rock failure by the modified Lade criterion (Ewy 1999). This work also developed a trial-and-error procedure to predict cutting forces, and the stress state of a rock before cutting process is also considered. A complete verification of the cutter model is conducted. The model results (i.e., predicted cutting forces) are compared with measured cutting forces from cutter tests in multiple published articles. The major influencing factors on cutting forces—backrake angle, side-rake angle, depths of cut, worn depth (or wear flat area), and hydrostatic pressure—are all studied and verified. A good agreement between the model results and cutter test data is found, and the overall mean relative error is approximately 15%. The influence of inhomogeneous precut stress state of a rock is also studied. Overall, the cutter model in this paper is complete and accurate. It is ready to be integrated into a PDC bit model.
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Liu, Chun, Zhongyi Man, Fubao Zhou, Kai Chen, and Haiyang Yu. "The Wear and Friction Characters of Polycrystalline Diamond Under Wetting Conditions." Journal of Tribology 141, no. 2 (November 1, 2018). http://dx.doi.org/10.1115/1.4041397.
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Polycrystalline diamond compacts (PDCs) are the main cutting unit of drill bits and are a major factor in determining the drilling efficiency and service life of drill bits. Drill bit failure is caused by the severe abrasive wear it undergoes during the drilling process. The drill bit failure can prolong the drilling period, which can result in borehole instability and cause collapse in the material. A solution that can address this issue is developing an appropriate drilling method that can expel the dust in a manner that will not increase the abrasive wear on the drill bit. Here, an Amsler friction and wear-testing machines was used to investigate the friction and wear characteristics of PDC and to study the effects of the dust expelled during drilling on the wear performance of drill bits under dry air and wetting conditions. The microstructures of the worn surfaces were examined by a scanning electron microscope (SEM) and metalloscope. In addition, the chemical compositions of the PDCs' surfaces were analyzed using X-ray diffraction (XRD) after the wear and friction tests. The results demonstrate that the friction coefficients and wear rate obtained in dry air were higher than those under wetting conditions. As expected, these values are mainly ascribed to the absence of the absorber layer and lubrication under dry air. Furthermore, under wetting conditions a number of cracks were observed on the PDC surface after testing at 700 °C, which was mainly caused by two factors: The different thermal expansion coefficients between the diamond and Cobalt phase; and the residual stress generated inside the PDC under wetting conditions.
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Che, Demeng, Peidong Han, Ping Guo, and Kornel Ehmann. "Issues in Polycrystalline Diamond Compact Cutter–Rock Interaction From a Metal Machining Point of View—Part I: Temperature, Stresses, and Forces." Journal of Manufacturing Science and Engineering 134, no. 6 (October 17, 2012). http://dx.doi.org/10.1115/1.4007468.
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This paper provides a comprehensive review of the literature that deals with issues surrounding the polycrystalline diamond compact (PDC) cutter–rock interface during rock cutting/drilling processes. The paper is separated into two parts addressing eight significant issues: Part I deals with fundamental issues associated with temperature/stress distribution and loading force prediction, while Part II focuses on issues related to PDC cutter/bit performance, wear and other failure phenomena, rock removal mechanism and cutting theory, rock properties, and numerical modeling of cutter–rock interaction. Experimental, analytical, and numerical methods are included into the investigation of the above-mentioned eight issues. Relevant concepts from metal cutting, micromachining, and other machining processes are also introduced to provide important insights and draw parallels between these interrelated fields.
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Mazen, Ahmed Z., Nejat Rahmanian, Iqbal Mujtaba, and Ali Hassanpour. "Prediction of Penetration Rate for PDC Bits Using Indices of Rock Drillability, Cuttings Removal, and Bit Wear." SPE Drilling & Completion, November 1, 2020. http://dx.doi.org/10.2118/204231-pa.
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