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.
Issue Section:
Research Papers
References
1.
Che
, D.
, Han
, P.
, Peng
, B.
, and Ehmann
, K. F.
, 2014
, “Finite Element Study on Chip Formation and Force Response in Two-Dimensional Orthogonal Cutting of Rock
,” ASME
Paper No. MSEC2014-3952.2.
Che
, D.
, Saxena
, I.
, Han
, P.
, Guo
, P.
, and Ehmann
, K. F.
, 2014
, “Machining of Carbon Fiber Reinforced Plastics/Polymers: A Literature Review
,” ASME J. Manuf. Sci. Eng.
, 136
(3
), p. 034001
.3.
Che
, D.
, Han
, P.
, Guo
, P.
, and Ehmann
, K.
, 2012
, “Issues in Polycrystalline Diamond Compact Cutter-Rock Interaction From a Metal Machining Point of View—Part I: Temperature, Stresses, and Forces
,” ASME J. Manuf. Sci. Eng.
, 134
(6
), p. 064001
.4.
Bruton
, G.
, Crockett
, R.
, Taylor
, M.
, DenBoer
, D.
, Lund
, J.
, Fleming
, C.
, Ford
, R.
, Garcia
, G.
, and White
, A.
, 2014
, “PDC Bit Technology for the 21st Century
,” Oilfield Rev.
, 26
(2
), pp. 48
–57
.5.
Che
, D.
, Han
, P.
, Guo
, P.
, and Ehmann
, K.
, 2012
, “Issues in Polycrystalline Diamond Compact Cutter-Rock Interaction From a Metal Machining Point of View—Part II: Bit Performance and Rock Cutting Mechanics
,” ASME J. Manuf. Sci. Eng.
, 134
(6
), p. 064002
.6.
Saxena
, I.
, and Ehmann
, K. F.
, 2014
, “Multimaterial Capability of Laser Induced Plasma Micromachining
,” ASME J. Micro Nano-Manuf.
, 2
(3
), p. 031005
.7.
Saxena
, I.
, Ehmann
, K.
, and Cao
, J.
, 2015
, “High Throughput Microfabrication Using Laser Induced Plasma in Saline Aqueous Medium
,” J. Mater. Process. Technol.
, 217
, pp. 77
–87
.8.
Saxena
, I.
, Malhotra
, R.
, Ehmann
, K.
, and Cao
, J.
, 2015
, “High-Speed Fabrication of Micro-Channels Using Line-Based Laser Induced Plasma Micromachining (L-LIPMM)
,” ASME J. Micro Nano-Manuf.
, 3
(2
), p. 021006
.9.
Venkatachalam
, S.
, Fergani
, O.
, Li
, X.
, Guo Yang
, J.
, Chiang
, K.-N.
, and Liang
, S. Y.
, 2015
, “Microstructure Effects on Cutting Forces and Flow Stress in Ultra-Precision Machining of Polycrystalline Brittle Materials
,” ASME J. Manuf. Sci. Eng.
, 137
(2
), p. 021020
.10.
Kalyanasundaram
, D.
, Schmidt
, A.
, Molian
, P.
, and Shrotriya
, P.
, 2014
, “Hybrid CO2 Laser/Waterjet Machining of Polycrystalline Diamond Substrate: Material Separation Through Transformation Induced Controlled Fracture
,” ASME J. Manuf. Sci. Eng.
, 136
(4
), p. 041001
.11.
Che
, D.
, and Ehmann
, K.
, 2014
, “Experimental Study of Force Responses in Polycrystalline Diamond Face Turning of Rock
,” Int. J. Rock Mech. Min. Sci.
, 72
(0
), pp. 80
–91
.12.
Glowka
, D. A.
, 1986
, “The Use of Single-Cutter Data in the Analysis of PDC Bit Designs
,” Society of Petroleum Engineers Annual Technical Conference and Exhibition
, New Orleans, LA, Oct. 5.13.
Bellin
, F.
, Dourfaye
, A.
, King
, W.
, and Thigpen
, M.
, 2010
, “The Current State of PDC Bit Technology
,” World Oil
, 231
(10
), pp. 53
–58
.14.
Durrand
, C. J.
, Skeem
, M. R.
, Crockett
, R. B.
, and Hall
, D. R.
, 2010
, “Super-Hard, Thick, Shaped PDC Cutters for Hard Rock Drilling: Development and Test Results
,” 35th Workshop on Geothermal Reservoir Engineering
, Standford, CA, Feb. 1–3.15.
Che
, D.
, Smith
, J.
, and Ehmann
, K.
, 2015
, “Finite Element Study of the Cutting Mechanics of the Three Dimensional Rock Turning Process
,” ASME
Paper No. MSEC2015-9249.16.
Aluko
, O. B.
, and Seig
, D. A.
, 2000
, “An Experimental Investigation of the Characteristics of and Conditions for Brittle Fracture in Two-Dimensional Soil Cutting
,” Soil and Tillage Res.
, 57
(3
), pp. 143
–157
.17.
Copur
, H.
, 2010
, “Linear Stone Cutting Tests With Chisel Tools for Identification of Cutting Principles and Predicting Performance of Chain Saw Machines
,” Int. J. Rock Mech. Min. Sci.
, 47
(1
), pp. 104
–120
.18.
Li
, H.
, Butt
, S.
, Munaswamy
, K.
, and Arvani
, F.
, 2010
, “Experimental Investigation of Bit Vibration on Rotary Drilling Penetration Rate
,” 44th U.S. Rock Mechanics Symposium and 5th U.S.-Canada Rock Mechanics Symposium
, Salt Lake City, UT, June 27–30, pp. 10
–426
.19.
Franca
, L. F. P.
, 2011
, “A Bit–Rock Interaction Model for Rotary–Percussive Drilling
,” Int. J. Rock Mech. Min. Sci.
, 48
(5
), pp. 827
–835
.20.
Li
, X. B.
, Summers
, D. A.
, Rupert
, G.
, and Santi
, P.
, 2001
, “Experimental Investigation on the Breakage of Hard Rock by the PDC Cutters With Combined Action Modes
,” Tunnelling Underground Space Technol.
, 16
(2
), pp. 107
–114
.21.
Balci
, C.
, 2009
, “Correlation of Rock Cutting Tests With Field Performance of a TBM in a Highly Fractured Rock Formation: A Case Study in Kozyatagi-Kadikoy Metro Tunnel, Turkey
,” Tunnelling Underground Space Technol.
, 24
(4
), pp. 423
–435
.22.
Che
, D.
, and Ehmann
, K.
, 2013
, “Polycrystalline Diamond Turning of Rock
,” ASME
Paper No. MSEC2013-1127.23.
Geoffroy
, H.
, and Minh
, D. N.
, 1997
, “Study on Interaction Between Rocks and Worn PDC'S Cutter
,” Int. J. Rock Mech. Min. Sci.
, 34
(3–4
), pp. 95.e91
–95.e15
.24.
Hamade
, R. F.
, Manthri
, S. P.
, Pusavec
, F.
, Zacny
, K. A.
, Taylor
, L. A.
, Dillon
, O. W.
, Jr., Rouch
, K. E.
, and Jawahir
, I. S.
, 2010
, “Compact Core Drilling in Basalt Rock Using PCD Tool Inserts: Wear Characteristics and Cutting Forces
,” J. Mater. Process. Technol.
, 210
(10
), pp. 1326
–1339
.25.
Rao
, K. U. M.
, Bhatnagar
, A.
, and Misra
, B.
, 2002
, “Laboratory Investigations on Rotary Diamond Drilling
,” Geotech. Geol. Eng.
, 20
(1
), pp. 1
–16
.26.
Appl
, F. C.
, Wilson
, C. C.
, and Lakshman
, I.
, 1993
, “Measurement of Forces, Temperatures and Wear of PDC Cutters in Rock Cutting
,” Wear
, 169
(1
), pp. 9
–24
.27.
Wilson
, C.
, and Vorono
, O. A.
, 2003
, “Diamond Turning of Granite
,” Key Eng. Mater.
, 250
, pp. 138
–146
.28.
Che
, D.
, Smith
, J.
, and Ehmann
, K.
, 2014
, “Heat Transfer in Polycrystalline Diamond Compact Cutters in Rock Turning
,” International Symposium on Flexible Automation
, p. ISFA2014-2036L
.29.
Che
, D.
, Ehmann
, K.
, and Cao
, J.
, 2015
, “Analytical Modeling of Heat Transfer in Polycrystalline Diamond Compact Cutters in Rock Turning Processes
,” ASME J. Manuf. Sci. Eng.
, 137
(3
), p. 031005
.30.
Cheatham
, J. J. B.
, and Daniels
, W. H.
, 1979
, “A Study of Factors Influencing the Drillability of Shales: Single-Cutter Experiments With STRATAPAX Drill Blanks
,” ASME J. Energy Resour. Technol.
, 101
(3
), pp. 189
–195
.31.
Finger
, J. T.
, and Glowka
, D. A.
, 1989
, “PDC Bit Research at Sandia National Laboratories
,” Sandia National Laboratories, Report No. SAND89-0079
.32.
Xue
, J.
, Xia
, Y.
, Ji
, Z.
, and Zhou
, X.
, 2009
, “Soft Rock Cutting Mechanics Model of TBM Cutter and Experimental Research
,” Intelligent Robotics and Applications
, M.
Xie
, Y.
Xiong
, C.
Xiong
, H.
Liu
, and Z.
Hu
, eds., Springer
, Berlin, Heidelberg, Germany
, pp. 383
–391
.33.
Kaitkay
, P.
, and Lei
, S.
, 2005
, “Experimental Study of Rock Cutting Under External Hydrostatic Pressure
,” J. Mater. Process. Technol.
, 159
(2
), pp. 206
–213
.34.
Verhoef
, P. N. W.
, and Ockeloen
, J. J.
, 1996
, “The Significance of Rock Ductility for Mechanical Rock Cutting
,” Rock Mech. Tools Tech.
, 1
, pp. 709
–716
.35.
Tiryaki
, B.
, and Dikmen
, A. C.
, 2006
, “Effects of Rock Properties on Specific Cutting Energy in Linear Cutting of Sandstones by Picks
,” Rock Mech. Rock Eng.
, 39
(2
), pp. 89
–120
.36.
Balci
, C.
, and Bilgin
, N.
, 2007
, “Correlative Study of Linear Small and Full-Scale Rock Cutting Tests to Select Mechanized Excavation Machines
,” Int. J. Rock Mech. Min. Sci.
, 44
(3
), pp. 468
–476
.37.
Richard
, T.
, Dagrain
, F.
, Poyol
, E.
, and Detournay
, E.
, 2012
, “Rock Strength Determination From Scratch Tests
,” Eng. Geol.
, 147–148
, pp. 91
–100
.38.
Goodman
, R. E.
, 1989
, Introduction to Rock Mechanics
, Wiley
, New York.39.
Kocurek Industries
, 2015
, “Rock Products
,” Kocurek Industries, Caldwell, TX
.40.
Hill
, J. R.
, 2015
, “Indiana Limestone
,” Indiana Geological Survey
, Bloomington, IN.41.
Wise
, J. L.
, Raymond
, D. W.
, Cooley
, C. H.
, and Bertagnolli
, K.
, 2002
, “Effects of Design and Processing Parameters on Performance of PDC Drag Cutters for Hard-Rock Drilling
,” Trans.-Geotherm. Resour. Counc.
, 26
, pp. 201
–206
.42.
Mishnaevsky
, L. L.
, 1995
, “Physical Mechanisms of Hard Rock Fragmentation Under Mechanical Loading: A Review
,” Int. J. Rock Mech. Min. Sci. Geomech. Abstr.
, 32
(8
), pp. 763
–766
.43.
Huang
, H.
, and Detournay
, E.
, 2008
, “Intrinsic Length Scales in Tool-Rock Interaction
,” Int. J. Geomech.
, 8
(1
), pp. 39
–44
.44.
Richard
, T.
, 1999
, “Determination of Rock Strength From Cutting Tests
,” M.S. thesis
, University of Minnesota, Minneapolis, MN.45.
Jaime
, M. C.
, Gamwo
, I. K.
, Lyons
, D. K.
, and Lin
, J. S.
, 2010
, “Finite Element Modeling of Rock Cutting
,” 44th U.S. Rock Mechanics Symposium and 5th U.S.-Canada Rock Mechanics Symposium
, American Rock Mechanics Association, Salt Lake City, UT, June 27–30, pp. 10
–231
.46.
Nishimatsu
, Y.
, 1972
, “The Mechanics of Rock Cutting
,” Int. J. Rock Mech. Min. Sci.
, 9
(2
), pp. 261
–270
.47.
Huang
, H.
, Lecampion
, B.
, and Detournay
, E.
, 2013
, “Discrete Element Modeling of Tool-Rock Interaction I: Rock Cutting
,” Int. J. Numer. Anal. Methods Geomech.
, 37
(13
), pp. 1913
–1929
.48.
Coudyzer
, C.
, and Richard
, T.
, 2005
, “Influence of the Back and Side Rake Angles in Rock Cutting
,” AADE 2005 National Technical Conference and ExhibitionWyndam Greenspoint
, Houston, TX, Apr. 5–7, p. AADE-05-NTCE-75
.49.
Halley
, J. M.
, and Kunin
, W. E.
, 1999
, “Extinction Risk and the 1/f Family of Noise Models
,” Theor. Popul. Biol.
, 56
(3
), pp. 215
–230
.50.
Bak
, P.
, Tang
, C.
, and Wiesenfeld
, K.
, 1987
, “Self-Organized Criticality: An Explanation of the 1/f Noise
,” Phys. Rev. Lett.
, 59
(4
), pp. 381
–384
.Copyright © 2017 by ASME
You do not currently have access to this content.
