Skip to main content
SpringerLink
Log in

Full-phase optimization of PDC bit cutter layout to reduce lateral force based on zoning method

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

Balancing lateral force is essential to reduce bit vibrations and prolong bit service life. During the process of cutting, the instantaneous cutting situation is governed by the previous blades cutting. This paper introduces a notion called "zoning method" based on the cutting geometry of bit-rock interface, which is dedicated to distinguishing different phases of cutting. Furthermore, a full-phase optimization model is developed to optimize cutter layout for minimizing the lateral force in each cutting phase, the NSGA-II is used to solve for the Pareto-optimal solutions, and the fuzzy comprehensive evaluation method is used to select the optimal solution. Finally, a case study of full-phase optimization of PDC bit cutter layout is conducted to highlight the advantage of the zoning method. The case study results show that the lateral force is reduced significantly in each cutting phase by using zoning method, which can help to achieve the real lateral force balance of PDC bit.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Abbreviations

A :

Cutting area

F c :

Cutting force

F n :

Positive pressure

F r :

Force component of Fn in radial direction

F r :

Force component of Fc in radial direction

F s :

Lateral force

F v :

Force component of Fn in axial direction

F x :

Force component of Fs in the x-direction

F y :

Force component of Fs in the y-direction

K d :

Rock drillability

m :

Number of blades

n :

Number of cutters

T :

Torque on bit

u :

Membership degree

v :

Cutting speed of cutter

w :

Cutting arc length

W :

Weight on bit

a :

Back-rake angle

β :

Side-rake angle

γ :

Normal angle

θ c :

Circumferential angle

R c :

Radial position

H c :

Axial position

References

  1. T. Ohno, H. Karasawa and H. Kobayashi, Cost reduction of polycrystalline diamond compact bits through improved durability, Geothermics, 31(2) (2002) 245–262.

    Article  Google Scholar 

  2. P. Chen, S. Z. Miska, R. Ren, M. Yu, E. Ozbayoglu and N. Takach, Poroelastic modeling of cutting rock in pressurized condition, Journal of Petroleum Science and Engineering, 169 (2018) 623–635.

    Article  Google Scholar 

  3. P. Chen, M. Meng, S. Miska, M. Yu, E. Ozbayoglu and N. Takach, Study on integrated effect of PDC double cutters, Journal of Petroleum Science and Engineering, 178 (2019) 1128–1142.

    Article  Google Scholar 

  4. T. Cao, K. Yu, W. Li, X. Chen and H. Zhu, Theoretical and experimental studies of internal cuttings removal bit, Journal of Energy Resources Technology, 143(4) (2020) 043002.

    Article  Google Scholar 

  5. R. K. Abbas, A review on the wear of oil drill bits (conventional and the state of the art approaches for wear reduction and quantification), Engineering Failure Analysis, 90 (2018) 554–584.

    Article  Google Scholar 

  6. J. Zhang and Y. Hu, Mechanical behavior and sealing performance of metal sealing system in roller cone bits, Journal of Mechanical Science and Technology, 33(6) (2019) 2855–2862.

    Article  Google Scholar 

  7. H. L. Monteiro and M. A. Trindade, Performance analysis of proportional-integral feedback control for the reduction of stick-slip-induced torsional vibrations in oil well drillstrings, Journal of Sound and Vibration, 398 (2017) 28–38.

    Article  Google Scholar 

  8. A. K. Abbas, R. E. Flori and M. Alsaba, Stability analysis of highly deviated boreholes to minimize drilling risks and nonproductive time, Journal of Energy Resources Technology, 141(8) (2019) 082094.

    Article  Google Scholar 

  9. X. Wang, H. Ni, R. Wang, L. Zhang and P. Wang, Drag-reduction and resonance problems of a jointed drillstring in the presence of an axial excitation tool, Journal of Energy Resources Technology, 141(3) (2019) 032904.

    Article  Google Scholar 

  10. J. Tian, L. Wei, L. Yang, L. Dai, T. Zhang and H. Liu, Research and experimental analysis of drill string dynamics characteristics and stick-slip reduction mechanism, Journal of Mechanical Science and Technology, 34(3) (2020) 977–986.

    Article  Google Scholar 

  11. K. Bybee, New bit design and cutter technology extend PDC applications to hard-rock drilling, Journal of Petroleum Technology, 57(12) (2005) 63–64.

    Article  Google Scholar 

  12. Z.-c. Guan, H. Wang, Y.-c. Shi, W.-q. Chen, G.-s. Zhao, J.-y. Wang and G.-q. Cao, Dynamic behavior analysis of push-the-bit rotary steerable bottom hole assembly, Journal of Mechanical Science and Technology, 33(4) (2019) 1501–1511.

    Article  Google Scholar 

  13. Y. Ma, Z. Huang, Q. Li, Y. Zhou and S. Peng, Cutter layout optimization for reduction of lateral force on PDC bit using Kriging and particle swarm optimization methods, Journal of Petroleum Science and Engineering, 163 (2018) 359–370.

    Article  Google Scholar 

  14. J. F. Brett, T. M. Warren and S. M. Behr, Bit whirl: a new theory of PDC bit failure, SPE Annual Technical Conference and Exhibition, Society of Petroleum Engineers, San Antonio, Texas, USA (1989).

    Google Scholar 

  15. S. Behr, T. Warren, L. Sinor and J. Brett, 3D PDC bit model predicts higher cutter loads, SPE Drilling and Completion, 8(4) (1993) 253–258.

    Article  Google Scholar 

  16. C. Langeveld, PDC bit dynamics, SPE/IADC Drilling Conference, Society of Petroleum Engineers, New Orleans, Louisiana, USA (1992).

    Book  Google Scholar 

  17. T. M. Warren, J. F. Brett and L. A. Sinor, Development of a whirl-resistant bit, SPE Drilling Engineering, 5(4) (1990) 267–275.

    Article  Google Scholar 

  18. G. Mensa-Wilmot and T. Krepp, Innovative cutting structure improves stability and penetration rate of PDC bits without sacrificing durability, IADC/SPE Drilling Conference, Society of Petroleum Engineers, Dallas, Texas, USA (1998).

    Google Scholar 

  19. D. Zou and R. Wang, Lateral force balancing design of blade PDC bits, Journal of China University of Petroleum (Edition of Natural Science), 29(2) (2005) 42–44.

    Google Scholar 

  20. D. Zou, J. Zhang and R. Wang, The experiment study on mechanical model of PDC bits, Petroleum Drilling Techniques, 33(2) (2005) 41–43.

    Google Scholar 

  21. X. Liu, X. Long, X. Zheng, G. Meng and B. Balachandran, Spatial-temporal dynamics of a drill string with complex time-delay effects: bit bounce and stick-slip oscillations, International Journal of Mechanical Sciences, 170 (2020) 105338.

    Article  Google Scholar 

  22. X. Liu, N. Vlajic, X. Long, G. Meng and B. Balachandran, Multiple regenerative effects in cutting process and nonlinear oscillations, International Journal of Dynamics and Control, 2(1) (2014) 86–101.

    Article  Google Scholar 

  23. J. Tlusty and F. Ismail, Basic non-linearity in machining chatter, CIRP Annals, 30(1) (1981) 299–304.

    Article  Google Scholar 

  24. K. Deb, A. Pratap, S. Agarwal and T. Meyarivan, A fast and elitist multiobjective genetic algorithm: NSGA-II, IEEE Transactions on Evolutionary Computation, 6(2) (2002) 182–197.

    Article  Google Scholar 

  25. C. Hongwei, F. Qihong, Z. Xianmin, W. Sen, Z. Wensheng and L. Fan, Well placement optimization with cat swarm optimization algorithm under oilfield development constraints, Journal of Energy Resources Technology, 141(1) (2019) 012902.

    Article  Google Scholar 

  26. K. Deb, M. Mohan and S. Mishra, Evaluating the ε-domination based multi-objective evolutionary algorithm for a quick computation of pareto-optimal solutions, Evolutionary Computation, 13(4) (2005) 501–525.

    Article  Google Scholar 

  27. T. Vo-Duy, D. Duong-Gia, V. Ho-Huu, H. Vu-Do and T. Nguyen-Thoi, Multi-objective optimization of laminated composite beam structures using NSGA-II algorithm, Composite Structures, 168 (2017) 498–509.

    Article  Google Scholar 

  28. J. M. Keller and D. J. Hunt, Incorporating fuzzy membership functions into the perceptron algorithm, IEEE Transactions on Pattern Analysis and Machine Intelligence, PAMI-7(6) (1985) 693–699.

    Article  Google Scholar 

  29. P. Melin, E. Ontiveros-Robles, C. I. Gonzalez, J. R. Castro and O. Castillo, An approach for parameterized shadowed type-2 fuzzy membership functions applied in control applications, Soft Computing, 23(11) (2019) 3887–3901.

    Article  MATH  Google Scholar 

  30. D. A. Glowka, Use of single-cutter data in the analysis of PDC bit designs: part 1-development of a PDC cutting force model, Journal of Petroleum Technology, 41(8) (1989) 797–849.

    Article  Google Scholar 

Download references

Acknowledgments

This work was financially supported by the National Natural Science Foundation of China (Grant numbers: 51804322; 51821092; 51774301; U1762214), National Key Research and Development Project (Grant numbers: 2017ZX05009-003; 2017ZX05005-005-007; 2016YFC0303303), and other projects (Grant numbers: 2462017YJRC050, SXCU-201903).

Author information

Authors and Affiliations

  1. College of Mechanical and Transportation Engineering, China University of Petroleum, Beijing, 102249, China

    Tong Cao, Kaian Yu, Hongwu Zhu & Rui Zhang

  2. Centre for Applied Dynamics Research, School of Engineering, University of Aberdeen, King’s College, Scotland, Aberdeen, AB24 3FX, UK

    Tong Cao

  3. MOE Key Laboratory of Petroleum Engineering, China University of Petroleum, Beijing, 102249, China

    Xuyue Chen

Authors
  1. Tong Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kaian Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xuyue Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hongwu Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Rui Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kaian Yu.

Additional information

Recommended by Editor Hyung Wook Park

Tong Cao is currently a Ph.D. student of the College of Mechanical and Transportation Engineering in China University of Petroleum, Beijing. His research interests include drill bit, downhole tools and drill-string dynamics.

Kaian Yu received his Ph.D. from Southwest Petroleum University, and is a Professor of the College of Mechanical and Transportation Engineering in China University of Petroleum, Beijing. His research interests include drill bit, downhole tools, rock mechanics and offshore oil equipment.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Cao, T., Yu, K., Chen, X. et al. Full-phase optimization of PDC bit cutter layout to reduce lateral force based on zoning method. J Mech Sci Technol 35, 1199–1207 (2021). https://doi.org/10.1007/s12206-021-0233-9

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-021-0233-9

Keywords

Search

Navigation