INVESTIGATE ON THE MIXED-CUTTING OF SPECIALLY-SHAPED PDC CUTTERS IN GRANITE
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摘要: 针对常规齿PDC钻头在硬地层钻进中出现的磨损大，崩齿、碎齿严重等问题，各种异形齿被广泛用于钻头设计。为探究和优化单一齿形及混合齿形PDC钻头的布齿间距，提高PDC齿在花岗岩地层的破岩效率，进行了相同形状PDC齿组合切削破岩室内试验和平面PDC齿与异形齿混合布齿数值仿真实验。研究结果表明：在切削花岗岩且切深为1.0 mm时，平面齿组合的最优布齿间距为10 mm，斧形齿为12 mm，锥形齿为3 mm，三平面齿为11 mm。混合布齿组合中，“平面齿+斧形齿”的最优布齿间距为6 mm，“平面齿+锥形齿”为8 mm，“平面齿+三平面齿”为9 mm。在不同的组合中，包含三平面齿的组合其破岩比功最低，破岩效率最高。研究结果对单一齿形钻头以及混合齿钻头的齿形选择和布齿间距优化具有重要的参考作用。Abstract: Due to the serious problems of cutter abrasiveness and damage in drilling by PDC bits with conventional cutters in hard formation, various specially shaped cutters have been widely used in the bit design. To explore and to optimize the cutter arrangement of PDC bits with the same or mixed shaped cutters and to improve the rock breaking efficiency in granite formation, the rock cutting test using the same shaped PDC cutters and rock cutting simulation of mixed cutters with planar cutters and specially shaped cutters are conducted. The results show that: the optimal space of cutters is 10 mm for the planar cutter, 12 mm for the axe-shaped cutter, 3 mm for the conical cutter and, 11 mm for the tri-plane cutter respectively with a cutting depth of 1.0 mm. In terms of the mixed cutter arrangement, the optimal space of cutters is 6 mm for 'planar and axe-shaped cutters', 8 mm for 'planar and conical cutters' and, 9 mm for 'planar and tri-planar cutters' in turn. Among the different combinations, the combination consisting of tri-plane cutters has the smallest mechanical specific energy and largest rock breaking efficiency. In general, the results of this study play a significant role in the selection of cutter shape for a single or a hybrid PDC bit and optimization of cutter gaps.
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Keywords:
- specially shaped cutter /
- granite /
- rock cutting /
- cutters gap /
- mixed cutter arrangement
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图 5 多齿切削破岩切削力随布齿间距的变化情况
Figure 5. The change of cutting force in multi-cutter cutting with spacing of cutter distribution
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图 6 多齿切削破岩比功随布齿间距的变化情况
Figure 6. The change of MSE in multi-cutter cutting with spacing of cutter distribution
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图 7 异形齿多齿切削破岩的岩屑
Figure 7. Cuttings from the rock breaking experiment of multi-cutter cutting with special-shaped cutters
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图 10 “平面齿+异形齿”组合切削花岗岩模型示意图
Figure 10. Schematic diagram of “planar cutter + special-shaped cutter” combined cutting granite model
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图 11 “平面齿+异形齿”组合切削花岗岩的切削力
Figure 11. Cutting force of ‘planar cutter + special-shaped cutter’combined cutting granite
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图 13 “平面齿+异形齿”组合切削花岗岩的破岩比功
Figure 13. MSE of ‘planar cutter + special-shaped cutter’ combined cutting granite
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图 14 “平面齿+异形齿”组合的破岩云图
Figure 14. Rock-breaking cloud map of the combination of ‘planar cutter + special-shaped cutter’
表 1 岩样的基本力学特性
Table 1 Basic mechanical properties of rock samples
岩样种类 弹性模量/GPa 泊松比 单轴抗压强度/MPa 抗拉强度/MPa 灰白色花岗岩 21.5 0.168 117.4 4.57 
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表 2 异形PDC齿布齿间距破岩特性研究实验参数
Table 2 Experimental parameters of rock breaking characteristics of PDC cutter spacing
齿形 前倾角/(°) 切削深度/mm 切削速度/(r/min) 布齿间距a/mm 平面齿 15 1.0 11 6，8、9，…，13，
16、17、18斧形齿 15 1.0 11 6，8、9，…，13，
16、17、18锥形齿 15 1.0 11 2、3、4，…，11 三平面齿 15 1.0 11 6，8、9，…，13，
16、17、18
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表 3 花岗岩矿物组份及材料属性
Table 3 Mineral composition and material properties of granite
矿物 质量分数/(%) 弹性模量/GPa 泊松比 抗压强度/MPa 微斜长石 41.1 53.0 0.130 147 钠长石 34.5 55.0 0.120 137 石英 12.2 75.0 0.080 187 白云母 7.8 32.0 0.160 167 绿泥石 4.4 48.0 0.140 137 粘结 − 22.2 0.168 67
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表 4 多齿切削组合方式及其切削参数
Table 4 Multi-cutter cutting combination and cutting parameters
组合方式 前排齿间距
a/mm钻齿前倾角β/(°) 切削速度v/(m/s) 切削深度d/mm 平面齿+斧形齿 6、8、9、10、
11、12、13、
16、17、1815 1.0 1.0 平面齿+锥形齿 平面齿+三平面齿
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