PDC磨损齿切削破岩数值模拟研究

蔡茂盛; 王红波; 张春江; 李赛; 程书婷

doi:10.13394/j.cnki.jgszz.2023.0258

PDC磨损齿切削破岩数值模拟研究

doi: 10.13394/j.cnki.jgszz.2023.0258

蔡茂盛^{1, 2},
王红波^{1, 2, ,},
张春江^{1, 2},
李赛^{1, 2},
程书婷³

1.
长江大学石油工程学院, 武汉 430100
2.
油气钻采工程湖北省重点实验室, 武汉 430100
3.
中石化石油机械股份有限公司, 武汉 430205

详细信息

通讯作者:
王红波，男，1978年生，博士后，硕士生导师。主要研究方向：钻井材料与机具、采油设备与破岩机理。E-mail: tmwangbo@163.com

中图分类号: TQ164; TG58; TG74
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- 被引次数: 0
出版历程
- 收稿日期: 2023-11-29
- 修回日期: 2024-02-21
- 录用日期: 2024-03-13
- 网络出版日期: 2024-06-05
- 刊出日期: 2024-12-06

Study on numerical simulation of rock breaking by PDC wear teeth cutting

CAI Maosheng^{1, 2},
WANG Hongbo^{1, 2
, ,},
ZHANG Chunjiang^{1, 2},
LI Sai^{1, 2},
CHENG Shuting³

1.
School of Petroleum Engineering, Yangtze University, Wuhan 430100, China
2.
Hubei Key Laboratory of Oil and Gas Drilling and Production Engineering, Wuhan 430100, China
3.
SINOPEC Oilfield Equipment Co., Ltd., Wuhan 430205, China

摘要

摘要: 现有文献针对切削齿的数值模拟研究较少考虑磨损高度对切削齿温度、切削载荷的影响，然而聚晶金刚石复合片（PDC）切削齿磨损后受力恶化、热磨损加剧会导致其快速失效。为探讨这一问题，基于弹塑性力学和岩石力学，以Drucker-Prager准则为岩石的本构模型建立磨损齿的三维动态旋切仿真模型，运用数值模拟的方法分析在不同磨损高度、切削深度、前倾角的条件下切削齿的受力状态以及温升幅度。结果表明：与未磨损齿相比，磨损齿的切削载荷随磨损高度的增加而变大，且切削齿（直径13.4 mm、总高8 mm）磨损高度为1.5 mm时达到最大；切削齿磨损越严重，吃入到同一深度所需的力越大；前倾角增加，导致切削载荷也会变大。因此磨损齿在切削钻进过程中，磨损高度越高、前倾角越大，切削齿的失效风险越高；随着切削齿磨损高度增加，切削齿温升显著增加，在模拟条件下可提高54%～103%。
- PDC切削齿 /
- Drucker-Prager准则 /
- 单齿切削 /
- 切削载荷 /
- 切削热
Abstract: Objectives: The existing literature on numerical simulation of cutters rarely considers the effect of wear height on the temperature and cutting load of cutters. However, the deterioration of force and the aggravation of thermal wear after the wear of polycrystalline diamond composite (PDC) cutters lead to their rapid failure. Therefore, it is particularly necessary to study the change of cutting load and the law of heat generation of worn cutters to extend their service life. Methods: Based on elastoplastic mechanics and rock mechanics, a 3D dynamic rotational simulation model of worn teeth is established with the Drucker-Prager criterion as the rock constitutive model. The stress state and temperature rise amplitude of cutting teeth under different wear heights, cutting depths, and front inclination angles are analyzed by numerical simulation. Results: (1) Influence of wear height on cutting load: Under simulated conditions (front inclination 15°, cutting depth 1.5 mm), the size and the fluctuation degree of cutting load increase with the increase of wear height when the wear height is 0−1.5 mm, and decrease slightly when the wear height is larger than 1.5 mm. In terms of tangential force, the cutter with a wear height of 1.5 mm is subjected to the largest tangential force, but when the wear height is 2.0 mm, the tangential force is reduced. In terms of axial force, the axial force of worn teeth is higher than that of unworn teeth. When the wear height is 0−1.5 mm, the axial force gradually increases with the increase of wear height. When the wear height is 1.5 mm, the axial force reaches its maximum, and when the wear height is larger than 1.5 mm, the axial force decreases. The axial force of the cutter with a wear height of 1.0 mm and wear height of 2.0 mm is exactly 1.2 times that of the unworn tooth, and the axial force of the cutter with a wear height of 1.5 mm is 1.3 times that of the unworn tooth. (2) Influence of cutting depth on cutting load: Under simulated conditions (wear height 1.0 mm, front inclination angle 15°), tangential force and axial force gradually increase with the increase of cutting depth, and the degree of fluctuation is more intense. In terms of tangential force, the tangential force of the worn tooth with the cutting depth of 2.0 mm is 1.9 times that of the worn tooth with the cutting depth of 1.0 mm, and the increase is larger. The tangential force of the worn tooth with the cutting depth of 1.5 mm is only 25% higher than that of the worn tooth with the cutting depth of 1.0 mm, and the increase is small. In terms of axial force, with the increase of cutting depth, the increase in axial force is relatively balanced. (3) Influence of front inclination angle on cutting load: Under simulated conditions (wear height 1.0 mm, cutting depth 1.5 mm), the cutting load of worn teeth gradually increases with the increase of front inclination angle, with the tangential force increasing by 28% and the axial force increasing by 32%. When the front angle is 10°, the fluctuation of the cutting load is more severe than at other time with 15° and 20°. (4) Influence of wear height on cutting heat: according to the temperature cloud map of the cutter, because the cutter rotates around the central axis to break rock, the linear speed of the cutting edge differs, and the temperature on the side away from the central axis will be higher than that on the side near the central axis. With the increase of wear degree, the temperature rise of the cutter becomes more significant, and the high-temperature area is concentrated in the cutting-cutter contact area, where plastic deformation and frictional heat generation are concentrated. The temperature change curve can be divided into three stages: rising period, transitional period, and stable period. With the passage of time, the temperature of the cutter continues to rise, and the temperature rise rate in the rising period is greater than in the transitional period, tending to flatten after entering the stable period. In the process of rock breaking, the temperature rise of worn teeth is much higher than that of unworn teeth, with a temperature increase of 54%−103%. Conclusions: The force on a cutter with excessive wear is more complex and variable, increasing the risk of fatigue failure. In terms of tooth layout, it can be considered to place the auxiliary cutting unit behind the main cutting unit composite sheet and make its exposure height lower than the composite sheet, which can effectively reduce the load on the main cutting gear and reduce the probability of overload damage to the cutting gear. The cutting load of the worn teeth increases with the increase of the front angle. Considering the fluctuation of cutting efficiency and load, the front angle should be controlled at 15°−20° as far as possible, which is beneficial to prolong the service life of the cutting teeth. After cutter wear, its ability to break rock is weakened, the rock pre-crushing area is reduced, and the way of cutting the rock gradually transitions from shear failure to extrusion failure, greatly reducing the rock-breaking efficiency of the cutter. In the process of cutting rock breaking, the temperature rise of the worn teeth is much higher than that of the unworn teeth, and the temperature rise increases with the increase of wear degree. Thus, the thermal wear of the cutting teeth will continue to intensify after wear, accelerating the wear and failure of the cutting teeth. In the subsequent cutting process, cutter of wear-resistant and high-temperature-resistant materials can be selected to reduce the weight on the bit and the speed of drilling while increasing the water power of the pump, effectively inhibiting thermal wear.
- PDC cutter /
- Drucker-Prager criterion /
- single tooth cutting /
- cutting load /
- cutting heat

HTML全文

图 1 岩石与切削齿的物理模型

Figure 1. Physical model of rock and cutter

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图 2 破岩受力分析

Figure 2. Rock breaking force analysis

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图 3 PDC切削齿破岩数值模拟模型

Figure 3. Numerical simulation model of rock breaking for PDC cutter

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图 4 切削齿切削破碎岩石应力场分布特征

Figure 4. Distribution characteristics of stress field in cutting broken rock with wear teeth

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图 5 不同磨损高度对切削载荷的影响

Figure 5. Influence of different wear heights on cutting loads

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图 6 不同切削深度对切削载荷的影响

Figure 6. Influence of different cutting depth on cutting load

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图 7 不同前倾角对切削载荷的影响

Figure 7. Influence of different front angles on cutting load

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图 8 切削齿温度云图

Figure 8. Cutter temperature cloud map

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图 9 不同磨损高度对切削热的影响

Figure 9. Effect of different wear heights on cutting heat

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表 1 PDC切削齿和岩石的参数

Table 1. Parameters of PDC cutters and rocks

材料	PDC	岩石
密度ρ / (kg·m⁻³)	3 510	2 580
弹性模量 E / GPa	890	25
泊松比 ν	0.077	0.150
热传导率 λ /（W·m⁻¹·℃⁻¹）	543.0	3.5
比热容 c /(J·kg⁻¹·℃⁻¹)	790	800
热膨胀系数 α / ℃⁻¹	2.5 × 10⁻⁶	12.0 × 10⁻⁶
内摩擦角 φ / (°)	—	42
抗压强度 σ_bc/ MPa	—	40

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表 2 切削齿破岩仿真方案

Table 2. Simulation scheme of cutter rock breaking

仿真方案	仿真参数
仿真方案	磨损高度 H / mm	前倾角 θ / (°)	切削深度 d_DOC / mm
方案一	0、1.0、1.5、2.0	15	1.5
方案二	1.0	10、15、20	1.5
方案三	1.0	15	1.0、1.5、2.0

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