Three-dimensional numerical simulation of the straight shale cutting process of single polycrystalline diamond cutter
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ORIGINAL PAPER
Three-dimensional numerical simulation of the straight shale cutting process of single polycrystalline diamond cutter Yijin Zeng 1,2 & Lianzhong Sun 1,2 & Xiaofeng Ran 3 & Yuezhi Wang 4 & Feifei Zhang 4 & Kai Wei 4 Received: 22 May 2020 / Accepted: 29 July 2020 # Saudi Society for Geosciences 2020
Abstract The finite element method offers a cost-effective way to test the performance of polycrystalline diamond compact (PDC) cutters, which is much cheaper than lab experiments. However, the finite element simulation often fails to output accurate results, owing to improper model selection and parameter setting. To solve the problem, this paper carries out a three-dimensional (3D) simulation of the straight shale cutting process of a single PDC cutter on finite element software Abaqus. The model size, material model, damage, and failure criterion were determined through triaxial tests on the shale. The adaptive meshing method and mass scaling were adopted to improve the calculation stability and reduce the simulation cost. The simulation reveals the residual stress field in the shale, the reaction force to the PDC cutter, and the relationship between the three components of the reaction force. Based on the simulation results, the authors explored the effects of back rake angle, side rake angle, cutting depth, cutter diameter, and confining pressure on the cutting force and vertical force. Our results were found consistent with those of the previous theoretical analyses and experiments. The numerical simulation of cutter-rock interaction provides an effective way for the design of new PDC cutters. Keywords Polycrystalline diamond compact (PDC) cutter . Numerical simulation . Rock cutting . Back rake angle . Confining pressure
Introduction For its excellence in rock breaking, polycrystalline diamond compact (PDC) bits have been widely used in oil drilling. But various challenges have arisen to the efficient application of PDC bits, as oil exploration shifts to deep formations and unconventional oil and gas fields (Menezes et al. 2014). To
This article is part of the Topical Collection on Big Data and Intelligent Computing Techniques in Geosciences * Xiaofeng Ran [email protected] 1
State Key Laboratory of Shale Oil and Gas Enrichment Mechanisms and Effective Development, Beijing 100101, China
2
Sinopec Research Institute of Petroleum Engineering, Beijing 100101, China
3
School of Mechanical Engineering, Yangtze University, Jingzhou 434023, China
4
School of Petroleum Engineering, Yangtze University, Wuhan 430100, China
cope with these challenges, it is necessary to design PDC bits capable of fast and high-quality drilling in specific formations. Therefore, many scholars have explored deep into the rock breaking mechanism of PDC bits as well as its influencing factors through theoretical analysis (Kuru and Wojtanowsicz 1988; Detournay and Defourny 1992; Rahmani et al. 2012), experiments (Kaitkay and Lei 2005; Cheng et al. 2018), and simulations (Wu et al. 2014; Cho et al. 2010). However, the r
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