Optimization of rock-breaking parameters under the combined intrusion and cutting action of Stinger PDC cutter

doi:10.3969/j.issn.2096-1693.2025.02.034

Abstract

Abstract:

The conical polycrystalline diamond compact (PDC) cutter demonstrates significant advantages in deep hard rock formations due to its excellent impact resistance, wear resistance, and efficient rock-breaking capabilities. To further enhance its rock-breaking efficiency in deep hard rock conditions, systematic optimization of the rock-breaking parameters of the conical PDC cutter is required. This paper focuses on the penetration-cutting combined rock-breaking process of the cutter during actual drilling, establishes a numerical calculation model for the conical PDC cutter breaking granite, and designs an orthogonal experimental scheme to conduct numerical simulations. Based on the results of the orthogonal experiments, the stepwise regression method is employed to fit and analyze key rock-breaking parameters such as cutting force, penetration ability, and mechanical specific energy. Subsequently, a multi-objective optimization method based on the non-dominated sorting genetic algorithm is applied to optimize and select the geometric parameters (cutter diameter, cone apex angle, cone apex radius) and operational parameters (inclination angle, weight on bit) of the conical PDC cutter. The research results indicate that, under the conditions of this study, the optimal geometric parameter combination for the conical PDC cutter is a bit diameter of 16 mm, a cone apex angle of 60°, and a cone apex radius of 1 mm, while the optimal operational parameter configuration is a bit inclination angle of 36° and a weight on bit of 925.65 N. The optimized mechanical specific energy is reduced by 10.99% compared to the initial combination. This study can provide theoretical and practical guidance for the optimization design of conical PDC bits.

Key words: Stinger PDC cutter, intrusion-cutting breaking rock, granite, numerical simulation, parameters optimization

摘要：

锥形聚晶金刚石复合片(PDC)齿凭借其优异的抗冲击性能、耐磨损特性及高效破岩能力，在深部硬岩地层钻井中展现出显著优势。为进一步提升其在深部硬岩条件下的破岩效率，需对锥形PDC齿的破岩参数进行系统优化。本文针对实际钻井过程中切削齿的侵入—切削联合破岩过程，建立了锥形PDC齿破碎花岗岩数值计算模型，并设计了正交试验方案开展数值模拟。基于正交试验结果，采用逐步回归法对切削力、侵入能力及破岩比能等关键破岩指标进行拟合分析，进而运用非支配排序遗传算法的多目标优化方法，对锥形PDC齿的几何参数(齿直径、锥顶角、锥顶半径)及工作参数(齿倾角、钻压)进行优化优选。研究结果表明：在本文设定的研究条件下，齿直径16 mm、锥顶角60°、锥顶半径1 mm为锥形PDC齿的最优几何参数组合，齿倾角36°、钻压925.65 N为其最优工作参数配置，优化后破岩比能较初始组合降低了10.99%。本研究可为锥形齿PDC钻头的优化设计提供理论依据与实践指导。

关键词: 锥形PDC齿, 侵入—切削破岩, 花岗岩, 数值模拟, 参数优化

CLC Number:

TE921
TH122

XIONG Chao, HE Senlin, HUANG Zhongwei, SHI Huaizhong, FENG Xiao, YANG Zixuan. Optimization of rock-breaking parameters under the combined intrusion and cutting action of Stinger PDC cutter[J]. Petroleum Science Bulletin, 2025, 10(6): 1267-1278.

熊超, 何森林, 黄中伟, 史怀忠, 冯枭, 杨子轩. 锥形PDC齿侵入—切削联合作用下破岩参数优化研究[J]. 石油科学通报, 2025, 10(6): 1267-1278.

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URL: https://sykxtb.cup.edu.cn/EN/10.3969/j.issn.2096-1693.2025.02.034

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Figures/Tables 16

References 34

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水平	因素
水平	α/°	r/mm	d/mm	β/°	P/N
1	60	0.5	12	0	800
2	70	1.0	13	10	1000
3	80	1.5	14	20	1200
4	90	2.0	15	30	1400
5	100	2.5	16	40	1600

水平	因素
水平	α/°	r/mm	d/mm	β/°	P/N
1	60	0.5	12	0	800
2	70	1.0	13	10	1000
3	80	1.5	14	20	1200
4	90	2.0	15	30	1400
5	100	2.5	16	40	1600

编号	影响因素					侵入能力/(N/mm) (I)	切向力/N (F)	破岩比能 /(J/mm³) (E_c)
编号	锥顶角/° (α)	锥顶半径/mm (r)	齿直径/mm (d)	齿倾角/° (β)	钻压/N (P)	侵入能力/(N/mm) (I)	切向力/N (F)	破岩比能 /(J/mm³) (E_c)
1	60	0.5	12	0	800	368.66	1225.21	187.45
2	60	1.0	14	30	1600	263.16	4178.73	128.18
3	60	1.5	16	10	1400	421.69	2463.45	166.06
4	60	2.0	13	40	1200	481.93	1767.67	139.71
5	60	2.5	15	20	1000	564.97	1252.90	138.06
6	70	0.5	16	30	1200	280.37	2561.58	121.47
7	70	1.0	13	10	1000	440.53	1565.35	172.05
8	70	1.5	15	40	800	444.44	1250.13	125.58
9	70	2.0	12	20	1600	606.06	2467.69	186.19
10	70	2.5	14	0	1400	760.87	1719.86	169.44
11	80	0.5	15	10	1600	544.22	2340.28	190.12
12	80	1.0	12	40	1400	530.30	2017.87	126.62
13	80	1.5	14	20	1200	517.24	1825.66	153.17
14	80	2.0	16	0	1000	704.23	1156.33	163.59
15	80	2.5	13	30	800	689.66	866.37	130.63
16	90	0.5	14	40	1000	800.00	949.25	159.35
17	90	1.0	16	20	800	540.54	1074.56	150.30
18	90	1.5	13	0	1600	816.33	1726.24	207.46
19	90	2.0	15	30	1400	823.53	1560.81	177.71
20	90	2.5	12	10	1200	759.49	1334.75	149.68
21	100	0.5	13	20	1400	686.27	1794.94	158.77
22	100	1.0	15	0	1200	697.67	1229.73	151.10
23	100	1.5	12	30	1000	806.45	1135.70	136.84
24	100	2.0	14	10	800	800.00	889.44	131.57
25	100	2.5	16	40	1600	-	558.30	533.90

编号	影响因素					侵入能力/(N/mm) (I)	切向力/N (F)	破岩比能 /(J/mm³) (E_c)
编号	锥顶角/° (α)	锥顶半径/mm (r)	齿直径/mm (d)	齿倾角/° (β)	钻压/N (P)	侵入能力/(N/mm) (I)	切向力/N (F)	破岩比能 /(J/mm³) (E_c)
1	60	0.5	12	0	800	368.66	1225.21	187.45
2	60	1.0	14	30	1600	263.16	4178.73	128.18
3	60	1.5	16	10	1400	421.69	2463.45	166.06
4	60	2.0	13	40	1200	481.93	1767.67	139.71
5	60	2.5	15	20	1000	564.97	1252.90	138.06
6	70	0.5	16	30	1200	280.37	2561.58	121.47
7	70	1.0	13	10	1000	440.53	1565.35	172.05
8	70	1.5	15	40	800	444.44	1250.13	125.58
9	70	2.0	12	20	1600	606.06	2467.69	186.19
10	70	2.5	14	0	1400	760.87	1719.86	169.44
11	80	0.5	15	10	1600	544.22	2340.28	190.12
12	80	1.0	12	40	1400	530.30	2017.87	126.62
13	80	1.5	14	20	1200	517.24	1825.66	153.17
14	80	2.0	16	0	1000	704.23	1156.33	163.59
15	80	2.5	13	30	800	689.66	866.37	130.63
16	90	0.5	14	40	1000	800.00	949.25	159.35
17	90	1.0	16	20	800	540.54	1074.56	150.30
18	90	1.5	13	0	1600	816.33	1726.24	207.46
19	90	2.0	15	30	1400	823.53	1560.81	177.71
20	90	2.5	12	10	1200	759.49	1334.75	149.68
21	100	0.5	13	20	1400	686.27	1794.94	158.77
22	100	1.0	15	0	1200	697.67	1229.73	151.10
23	100	1.5	12	30	1000	806.45	1135.70	136.84
24	100	2.0	14	10	800	800.00	889.44	131.57
25	100	2.5	16	40	1600	-	558.30	533.90

	非标准化系数		p	共线性诊断
	B	标准误差	p	VIF
常数	-341.552	109.143	0.0051	/
锥顶角(α)	9.669	1.242	1.263E-7	1.008
锥顶半径(r)	119.261	24.832	0.000 096	1.008
R²	0.787
F值	F(2, 21)=38.778，p=9.60×10^-5
D-W值	2.532

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