Analytical and Experimental Investigations of Rock Cutting Using Polycrystalline Diamond Compact Drag Cutters

1981 ◽  
Author(s):  
Daniel Vernon Swenson ◽  
Donald L. Wesenberg ◽  
Adrian K. Jones
Keyword(s):  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Experimental Investigations ◽  
Polycrystalline Diamond Compact

Analytical Modeling of Heat Transfer in Polycrystalline Diamond Compact Cutters in Rock Turning Processes

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Demeng Che ◽  
Kornel Ehmann ◽  
Jian Cao
Keyword(s):  
Heat Transfer ◽  
Analytical Solution ◽  
Transfer Problem ◽  
Mixed Boundary ◽  
Separation Of Variables ◽  
Polycrystalline Diamond ◽  
Experimental Tests ◽  
Rock Cutting ◽  
Polycrystalline Diamond Compact ◽  
Temperature Responses

Heat transfer phenomena at the rock–cutter interface are extremely significant since they affect the polycrystalline diamond compact (PDC) cutter's performance in rock cutting/drilling processes. The understanding of how temperature and heat flux responses in the cutter influence the intrinsic mechanisms of the rock–cutter interactions is an essential prerequisite for providing insights to enhance the performance of PDC cutters and to optimize rock cutting/drilling processes. In this paper, a mixed boundary value heat transfer problem was formulated to analytically describe the heat transfer phenomena in the PDC cutters during two-dimensional (2D) orthogonal rock cutting under steady state conditions. An analytical solution in the form of an infinite series was derived based on the method of separation of variables, the use of appropriate simplifications in the formulated problem and the separation of the thermal from the mechanical phenomena. A series of experimental tests were conducted on a newly developed rock cutting testbed to calibrate the process parameters in the analytical solution and then to confirm the validity of the assumed boundary conditions. The comparison between the newly derived analytical solution and the experimental data shows a good match in terms of temperature responses during rock cutting performed by PDC cutters.

Rock Cutter Interactions in Linear Rock Cutting

2016 ◽  
Author(s):  
Demeng Che ◽  
Weizhao Zhang ◽  
Kornel F. Ehmann
Keyword(s):  
Experimental Data ◽  
Oil And Gas ◽  
Cutting Tool ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Testing Methods ◽  
Gas Drilling ◽  
Complex Interactions ◽  
On Chip ◽  
Polycrystalline Diamond Compact

Polycrystalline diamond compact (PDC) cutter, as a major cutting tool, has been widely applied in oil and gas drilling processes. The understanding of the complex interactions at the rock and cutter interfaces are essential for the advancement of future drilling technologies, yet, these interactions are still not fully understood. Linear cutting of rock, among all the testing methods, avoids the geometric and process complexities and offer the most straightforward way to reveal the intrinsic mechanisms of rock cutting. Therefore, this paper presents an experimental study of the cutter’s cutting performance and the rock’s failure behaviors on a newly developed linear rock cutting facility. A series of rock cutting tests were designed and performed. The acquired experimental data was analyzed to investigate the influences of process parameter and the rock’s mechanical properties on chip formation and force responses.

Chip Formation and Force Responses in Linear Rock Cutting: An Experimental Study

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Demeng Che ◽  
Weizhao Zhang ◽  
Kornel Ehmann
Keyword(s):  
Experimental Study ◽  
Chip Formation ◽  
Oil And Gas ◽  
Cutting Tool ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Gas Drilling ◽  
Complex Interactions ◽  
On Chip ◽  
Polycrystalline Diamond Compact

Polycrystalline diamond compact (PDC) cutters, as a major cutting tool, have been widely applied in oil and gas drilling processes. The understanding of the complex interactions at the rock and cutter interfaces is essential for the advancement of future drilling technologies; yet, these interactions are still not fully understood. Linear cutting of rock, among all the testing methods, avoids the geometric and process complexities and offers the most straightforward way to reveal the intrinsic mechanisms of rock cutting. Therefore, this paper presents an experimental study of the cutter’s cutting performance and the rock’s failure behaviors on a newly developed linear rock cutting facility. A series of rock cutting tests were designed and performed. The acquired experimental data was analyzed to investigate the influences of process parameters and the rock’s mechanical properties on chip formation and force responses.

Issues in Polycrystalline Diamond Compact Cutter–Rock Interaction From a Metal Machining Point of View—Part II: Bit Performance and Rock Cutting Mechanics

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Demeng Che ◽  
Peidong Han ◽  
Ping Guo ◽  
Kornel Ehmann
Keyword(s):  
Metal Cutting ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Point Of View ◽  
Rock Interaction ◽  
Metal Machining ◽  
Pdc Bit ◽  
Rock Cutting Mechanics ◽  
Cutting Processes ◽  
Polycrystalline Diamond Compact

In Part I of this paper, the issues related to temperature, stress and force were reviewed and parallels were drawn between both metal machining and rock cutting. Part II discusses the issues more directly related to polycrystalline diamond compact (PDC) bit performance and rock mechanics. However, relevant issues in various metal cutting processes will continue to be presented to clarify the gaps and similarities between these two classes of processes.

Polycrystalline Diamond Turning of Rock

2013 ◽  
Author(s):  
Demeng Che ◽  
Kornel F. Ehmann
Keyword(s):  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Polycrystalline Diamond ◽  
Rock Cutting ◽  
Diamond Turning ◽  
Petroleum Engineering ◽  
Mechanical Responses ◽  
Turning Center ◽  
Polycrystalline Diamond Compact ◽  
Essential Prerequisite

Polycrystalline Diamond Compact (PDC) cutters, as the most commonly used inserts for rock cutting/drilling processes, are drawing increased attentions in manufacturing and petroleum engineering driven by the necessity to elevate cutter and process performance. The knowledge of the force response of single PDC cutters under various cutting conditions is an essential prerequisite for achieving this goal. In this paper, an analytical model is derived by extending Nishimatsu’s two-dimensional orthogonal cutting theory for rock cutting to the three-dimensional quasi-orthogonal case. A rock turning testbed that uses single PDC cutters is developed on a CNC turning center for measuring both thermal and mechanical responses at the rock-cutter interface in real-time. The developed testbed is used to perform the experimental validation of a newly proposed force prediction model.

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.

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