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Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters

Year 2023, Volume: 36 Issue: 1, 414 - 428, 01.03.2023

Pei Ju , Dongzhuang Tian , Hongjie Tian

https://doi.org/10.35378/gujs.927956

Abstract

In order to analyze the rock disintegration characteristics of special-shaped Polycrystalline Diamond Compact (PDC) cutters, numerical simulation and micro-drilling test on four kinds of special-shaped PDC cutters are carried out. Simulation results show that, the surface stress of each PDC cutter is quite different. For the dual-chamfer PDC cutter, the second chamfer can expand the stress on the cutting edge to a larger area; for the conical PDC cutter, the maximum stress is concentrated at the tip of the cone; for the ridged PDC cutter, the stress is distributed in a triangular fan shape from the lower edge of the cutting edge upward along the ridge, and for the triangular ridge PDC cutter, the stress is mainly distributed on the lowermost ridge. The conical PDC cutter has advantages in rock disintegration stability and efficiency, but it requires a higher weight on bit; the ridged PDC cutter has advantage in rock disintegration efficiency, but it tends to swing sideways when breaking rock; the dual-chamfer structure of PDC cutter is beneficial to extend the cutter’s life, but its rock disintegration efficiency is poor. Anchor bits with these special-shaped PDC cutters are produced, and electro-hydraulic micro-drilling test are carried out, the results of micro-drilling test and numerical simulation show the same law excluding conical PDC cutter. The research results can provide guidance for the application of special-shaped PDC cutters in drill bit.

Keywords

Special-shaped PDC cutter Numerical simulation Electro-hydraulic micro-drilling test Rock disintegration characteristic

Supporting Institution

Shaanxi Natural Science Basic Research Project

Project Number

2021 JQ-95

Thanks

This research was supported by the Shaanxi Natural Science Basic Research Project (No. 2021 JQ-952)

References

  • [1] Abbas, R. K. and Musa, K. M., “Using Raman shift and FT-IR spectra as quality indices of oil bit PDC cutters”, Petroleum, 5(3): 329-334, (2019).
  • [2] Huang, Z., Xie, D., Xie, B., Zhang, W. and Zhang, F., “Investigation of PDC bit failure base on stick-slip vibration analysis of drilling string system plus drill bit”, Journal of Sound and Vibration, 417: 97-109, (2018).
  • [3] Jaworska, L., O;szowka-Myslska, A., Cygan, S., Figiel, P., Karolus, M. and Cyboron, J., “The influence of tungsten carbide contamination from the milling process on PCD materials oxidation”, International Journal of Refractory Metals and Hard Materials, 64: 60-65, (2017).
  • [4] Osipov, A. S., Klimczyk, P., Cygan, S., Melniychuk, Y. A., Petrusha, I. A., Jaworska, L., and Bykov, A. I., “Diamond-CaCO3 and diamond-Li2CO3 materials sintered using the HPHT method”, Journal of the European Ceramic Society, 37(7): 2553-2558, (2017).
  • [5] Lu, J. R., Kou, Z. L., Liu, T., Yan, X. Z., Liu, F. M., Ding, W., Zhang, Q., Zhang, L. L., Liu, J. and He, D. W., “Submicron binderless polycrystalline diamond sintering under ultra-high pressure”, Diamond and Related Materials, 77: 41-45, (2017).
  • [6] Peng, Y. B., “Changes of microstructure and properties of cemented carbide substrate during the preparation of ultra-high pressure and high temperature composite PDC”, Cemented Carbide, 37(5): 345-349, (2020).
  • [7] Zhang, T., Lu, C. H., Dou, M., Liu, J. T. and Ning, J. L., “The research and development of high performance oil-drilling PCD”, Superhard Material Engineering, 29(3): 13-18, (2017).
  • [8] Dai, J. J., Chen, H. and Guo, D. M., “Residual stress of polycrystalline diamond compact”, Diamond Abrasives Engineering, 36(6): 57-62, (2016).
  • [9] Xu, L. H. and Bi, S. Y., “Overseas researches on PDC cutters”, China Petroleum Machinery, 45(2): 35-40, (2017).
  • [10] Schilling, J., Cooley, E., Azar, M., White, A., Koffler, K., McDonough, S., Self, J. and Krough, B., “Innovative conical diamond element bit significantly reduces drilling cost of laterals”, Proceedings of the IADC/SPE Asia Pacific Drilling Technology Conference, Singapore, 22-24 August, 1-12, (2016).
  • [11] Abdila, S. F., Sondang, J., Maaruf, P., Yoan, M. R., Noviasta, B., Astasari, K. and Febriarto, H., “Drilling optimisation in hard and abrasive basement rock using a conical diamond element bit”, Proceedings of the IADC/SPE Asia Pacific Drilling Technology Conference, Bangkok, Thailand, 27-29 August, 1-10, (2018).
  • [12] Crane, D., Zhang, Y. H., Douglas, C., Song, H. M., Gan, X. G., Lin, Z. J., Mueller, L., Skoff, G., Self, J. and Krough, B., “Innovative PDC cutter with elongated ridge combines shear and crush action to improve PDC bit performance”, Proceedings of the SPE Middle East Oil & Gas Show and Conference, Manama, Kingdom of Bahrain, 6-9 March, 1-17, (2017).
  • [13] Sharma, A., Narayanan, S., Zayyan, M., Prakash, S., Raghav, S. and Gounder, S., “Solving the deccan trap drilling challenge with innovative ridged and conical diamond elements technology”, Proceedings of the Abu Nhabi International Petroleum Exhibition & Conference, Abu Dhabi, UAE, 11-14 November, 1-14, (2019).
  • [14] Digiovanni, A., Stockey, D., Fuselier, D., Gavia, D., Zolnowsky, M., Philips, R. and Ridgway, D., “Innovative special-shaped face PDC cutters demonstrate 21% drilling efficiency improvement in interbedded shales and sand”, Proceedings of the 2014 IADC/SPE Drilling Conference and Exhibition, Fort Worth, Texas, USA, 4-6 March, 1-17, (2014).
  • [15] Oliveira, G. D., Freese, M. P., Izbinski, K. T., Valbuena, F., Carvalho, D. J. and Alonso, A., “Unique hybrid drill bit with novel PDC cutters improves performance in ultra-deepwater Brazil pre-salt application”, Proceedings of the Offshore Technology Conference Brasil held in Rio de Janeiro, Brazil, 27-29 October, 1-14, (2015).
  • [16] Nagaso, M., Mikada, H. and Takekawa, J., “The role of rock strength heterogeneities in complex hydraulic fracture formation–numerical simulation approach for the comparison to the effects of brittleness–”, Journal of Petroleum Science and Engineering, 172: 572-587, (2019).
  • [17] Saadat, M. and Taheri, A., “A numerical approach to investigate the effects of rock texture on the damage and crack propagation of a pre-cracked granite”, Computers & Geotechnics, 111: 89-111, (2019).
  • [18] Eremin, M., Esterhuizen, G. and Smolin, I., “Numerical simulation of roof cavings in several Kuzbass mines using finite-difference continuum damage mechanics approach”, International Journal of Mining Science and Technology, 30(2): 157-166, (2020).
  • [19] Ju, P. and Wang, C. L., “Simulation study on the cutter arrangement pattern of arc angle PDC drill bit”, Coal Geology & Exploration, 48(5): 244-249, (2020).
  • [20] Yari, N., Kapitaniak, M., Vaziri, V., Ma, L. F. and Wiercigroch, M., “Calibrated FEM modelling of rock cutting with PDC cutter”, Matec Web of Conference, 148: 1-4, (2018).
  • [21] Izbinski, K., Patel, S. G. and VanDeven, A., “Innovative dual-chamfer edge technology leads to performance gains in PDC bits”, Proceedings of the SPE/IADC Drilling Conference and Exhibition, London, United Kingdom, 17-19 March, 1-16, (2015).
  • [22] Zou, D. Y., Guo, Y. L. and Zhao, J., “Experimental study on rock disintegration of conical PDC cutter”, Petroleum Drilling Techniques, 43(1): 122-125, (2015).
  • [23] Armenta, M., Dykstra, M., Muesel, J., Marshall, E., Yango, T., Adeleye, O., Nagaraj, M. and Nasief, M., “Delivering best in class ROP performance by pushing the operational envelope with novel advanced bit designs”, Proceedings of the 2018 SPE Annual Technical Conference and Exhibition, Dallas, Texas, 24-26 September, 1-14, (2018).
  • [24] Zhao, D. P., Ma, S. S. and Niu, T. J., “Research of polycrystalline diamond compact having special-shaped surfaces for oil drilling”, Diamond Abrasives Engineering, 37(6): 49-52, (2017).
  • [25] Sun, Y. X., Zou, D. Y. and Hou, X. T., “Test of force of conical PDC cutter during rock plow-breaking”, China Petroleum Machinery, 42(9): 23-26, (2014).
  • [26] Xu, X. H., “Rock disintegration mechanics”, Coal Industry Press, Beijing, 184-208, (1984).

Year 2023, Volume: 36 Issue: 1, 414 - 428, 01.03.2023

Pei Ju , Dongzhuang Tian , Hongjie Tian

https://doi.org/10.35378/gujs.927956

Abstract

Project Number

2021 JQ-95

References

  • [1] Abbas, R. K. and Musa, K. M., “Using Raman shift and FT-IR spectra as quality indices of oil bit PDC cutters”, Petroleum, 5(3): 329-334, (2019).
  • [2] Huang, Z., Xie, D., Xie, B., Zhang, W. and Zhang, F., “Investigation of PDC bit failure base on stick-slip vibration analysis of drilling string system plus drill bit”, Journal of Sound and Vibration, 417: 97-109, (2018).
  • [3] Jaworska, L., O;szowka-Myslska, A., Cygan, S., Figiel, P., Karolus, M. and Cyboron, J., “The influence of tungsten carbide contamination from the milling process on PCD materials oxidation”, International Journal of Refractory Metals and Hard Materials, 64: 60-65, (2017).
  • [4] Osipov, A. S., Klimczyk, P., Cygan, S., Melniychuk, Y. A., Petrusha, I. A., Jaworska, L., and Bykov, A. I., “Diamond-CaCO3 and diamond-Li2CO3 materials sintered using the HPHT method”, Journal of the European Ceramic Society, 37(7): 2553-2558, (2017).
  • [5] Lu, J. R., Kou, Z. L., Liu, T., Yan, X. Z., Liu, F. M., Ding, W., Zhang, Q., Zhang, L. L., Liu, J. and He, D. W., “Submicron binderless polycrystalline diamond sintering under ultra-high pressure”, Diamond and Related Materials, 77: 41-45, (2017).
  • [6] Peng, Y. B., “Changes of microstructure and properties of cemented carbide substrate during the preparation of ultra-high pressure and high temperature composite PDC”, Cemented Carbide, 37(5): 345-349, (2020).
  • [7] Zhang, T., Lu, C. H., Dou, M., Liu, J. T. and Ning, J. L., “The research and development of high performance oil-drilling PCD”, Superhard Material Engineering, 29(3): 13-18, (2017).
  • [8] Dai, J. J., Chen, H. and Guo, D. M., “Residual stress of polycrystalline diamond compact”, Diamond Abrasives Engineering, 36(6): 57-62, (2016).
  • [9] Xu, L. H. and Bi, S. Y., “Overseas researches on PDC cutters”, China Petroleum Machinery, 45(2): 35-40, (2017).
  • [10] Schilling, J., Cooley, E., Azar, M., White, A., Koffler, K., McDonough, S., Self, J. and Krough, B., “Innovative conical diamond element bit significantly reduces drilling cost of laterals”, Proceedings of the IADC/SPE Asia Pacific Drilling Technology Conference, Singapore, 22-24 August, 1-12, (2016).
  • [11] Abdila, S. F., Sondang, J., Maaruf, P., Yoan, M. R., Noviasta, B., Astasari, K. and Febriarto, H., “Drilling optimisation in hard and abrasive basement rock using a conical diamond element bit”, Proceedings of the IADC/SPE Asia Pacific Drilling Technology Conference, Bangkok, Thailand, 27-29 August, 1-10, (2018).
  • [12] Crane, D., Zhang, Y. H., Douglas, C., Song, H. M., Gan, X. G., Lin, Z. J., Mueller, L., Skoff, G., Self, J. and Krough, B., “Innovative PDC cutter with elongated ridge combines shear and crush action to improve PDC bit performance”, Proceedings of the SPE Middle East Oil & Gas Show and Conference, Manama, Kingdom of Bahrain, 6-9 March, 1-17, (2017).
  • [13] Sharma, A., Narayanan, S., Zayyan, M., Prakash, S., Raghav, S. and Gounder, S., “Solving the deccan trap drilling challenge with innovative ridged and conical diamond elements technology”, Proceedings of the Abu Nhabi International Petroleum Exhibition & Conference, Abu Dhabi, UAE, 11-14 November, 1-14, (2019).
  • [14] Digiovanni, A., Stockey, D., Fuselier, D., Gavia, D., Zolnowsky, M., Philips, R. and Ridgway, D., “Innovative special-shaped face PDC cutters demonstrate 21% drilling efficiency improvement in interbedded shales and sand”, Proceedings of the 2014 IADC/SPE Drilling Conference and Exhibition, Fort Worth, Texas, USA, 4-6 March, 1-17, (2014).
  • [15] Oliveira, G. D., Freese, M. P., Izbinski, K. T., Valbuena, F., Carvalho, D. J. and Alonso, A., “Unique hybrid drill bit with novel PDC cutters improves performance in ultra-deepwater Brazil pre-salt application”, Proceedings of the Offshore Technology Conference Brasil held in Rio de Janeiro, Brazil, 27-29 October, 1-14, (2015).
  • [16] Nagaso, M., Mikada, H. and Takekawa, J., “The role of rock strength heterogeneities in complex hydraulic fracture formation–numerical simulation approach for the comparison to the effects of brittleness–”, Journal of Petroleum Science and Engineering, 172: 572-587, (2019).
  • [17] Saadat, M. and Taheri, A., “A numerical approach to investigate the effects of rock texture on the damage and crack propagation of a pre-cracked granite”, Computers & Geotechnics, 111: 89-111, (2019).
  • [18] Eremin, M., Esterhuizen, G. and Smolin, I., “Numerical simulation of roof cavings in several Kuzbass mines using finite-difference continuum damage mechanics approach”, International Journal of Mining Science and Technology, 30(2): 157-166, (2020).
  • [19] Ju, P. and Wang, C. L., “Simulation study on the cutter arrangement pattern of arc angle PDC drill bit”, Coal Geology & Exploration, 48(5): 244-249, (2020).
  • [20] Yari, N., Kapitaniak, M., Vaziri, V., Ma, L. F. and Wiercigroch, M., “Calibrated FEM modelling of rock cutting with PDC cutter”, Matec Web of Conference, 148: 1-4, (2018).
  • [21] Izbinski, K., Patel, S. G. and VanDeven, A., “Innovative dual-chamfer edge technology leads to performance gains in PDC bits”, Proceedings of the SPE/IADC Drilling Conference and Exhibition, London, United Kingdom, 17-19 March, 1-16, (2015).
  • [22] Zou, D. Y., Guo, Y. L. and Zhao, J., “Experimental study on rock disintegration of conical PDC cutter”, Petroleum Drilling Techniques, 43(1): 122-125, (2015).
  • [23] Armenta, M., Dykstra, M., Muesel, J., Marshall, E., Yango, T., Adeleye, O., Nagaraj, M. and Nasief, M., “Delivering best in class ROP performance by pushing the operational envelope with novel advanced bit designs”, Proceedings of the 2018 SPE Annual Technical Conference and Exhibition, Dallas, Texas, 24-26 September, 1-14, (2018).
  • [24] Zhao, D. P., Ma, S. S. and Niu, T. J., “Research of polycrystalline diamond compact having special-shaped surfaces for oil drilling”, Diamond Abrasives Engineering, 37(6): 49-52, (2017).
  • [25] Sun, Y. X., Zou, D. Y. and Hou, X. T., “Test of force of conical PDC cutter during rock plow-breaking”, China Petroleum Machinery, 42(9): 23-26, (2014).
  • [26] Xu, X. H., “Rock disintegration mechanics”, Coal Industry Press, Beijing, 184-208, (1984).
There are 26 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Mechanical Engineering
Authors

Pei Ju 0000-0003-0231-1120

Dongzhuang Tian 0000-0001-5863-3570

Hongjie Tian 0000-0001-9396-6370

Project Number 2021 JQ-95
Publication Date March 1, 2023
Published in Issue Year 2023 Volume: 36 Issue: 1

Cite

APA Ju, P., Tian, D., & Tian, H. (2023). Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters. Gazi University Journal of Science, 36(1), 414-428. https://doi.org/10.35378/gujs.927956
AMA Ju P, Tian D, Tian H. Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters. Gazi University Journal of Science. March 2023;36(1):414-428. doi:10.35378/gujs.927956
Chicago Ju, Pei, Dongzhuang Tian, and Hongjie Tian. “Simulation and Experimental Study on Rock Disintegration Characteristics of Special-Shaped PDC Cutters”. Gazi University Journal of Science 36, no. 1 (March 2023): 414-28. https://doi.org/10.35378/gujs.927956.
EndNote Ju P, Tian D, Tian H (March 1, 2023) Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters. Gazi University Journal of Science 36 1 414–428.
IEEE P. Ju, D. Tian, and H. Tian, “Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters”, Gazi University Journal of Science, vol. 36, no. 1, pp. 414–428, 2023, doi: 10.35378/gujs.927956.
ISNAD Ju, Pei et al. “Simulation and Experimental Study on Rock Disintegration Characteristics of Special-Shaped PDC Cutters”. Gazi University Journal of Science 36/1 (March 2023), 414-428. https://doi.org/10.35378/gujs.927956.
JAMA Ju P, Tian D, Tian H. Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters. Gazi University Journal of Science. 2023;36:414–428.
MLA Ju, Pei et al. “Simulation and Experimental Study on Rock Disintegration Characteristics of Special-Shaped PDC Cutters”. Gazi University Journal of Science, vol. 36, no. 1, 2023, pp. 414-28, doi:10.35378/gujs.927956.
Vancouver Ju P, Tian D, Tian H. Simulation and Experimental Study on Rock Disintegration Characteristics of Special-shaped PDC Cutters. Gazi University Journal of Science. 2023;36(1):414-28.