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Optimum design of the internal flushing channel of a drill bit using RSM and CFD simulation

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International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

In this study, a series of computational fluid dynamics (CFD) simulations was conducted to evaluate and optimize the design of the internal flushing channel for a drill bit. The Star-CCM+ code was used to simulate the multi-phase flow of flushing air and escaping rock particles during drilling work. The values of the input parameters used for the simulation were obtained from in-situ drilling test results. Finally after choosing three major design factors and determining their appropriate sizes, the experimental design method known as response surface methodology (RSM) was used to obtain the optimum value of each factor.

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Abbreviations

A P :

Projected area of the particle (m2)

C ε1, C ε2, C ε3, C ε4 :

Coefficients of turbulent dissipation rate

C d :

Drag coefficient

C vm :

Virtual mass coefficient

F b :

Particle body force (N)

F s :

Particle surface force (N)

f u :

User defined body force (N)

g :

Gravity acceleration (m s−2)

k :

Turbulent kinetic energy (m2 s−2)

m p :

Particles’ mass (kg)

\(\dot m_p\) :

Rate of mass transfer to the particle (kg s−1)

p :

Pressure (Pa)

p abs :

Absolute pressure (Pa)

∇p static :

Gradient of the static pressure in the continuous phase (Pa)

R :

Universal gas constant (J mol−1 K−1)

r p :

Position of the rock particle

T :

Fluid temperature (K)

t :

Time (s)

u′ i :

Fluctuant fluid velocity of i (i = x) (m s−1)

u′ j :

Fluctuant fluid velocity of j (j = y) (m s−1)

v i :

Fluid velocity in direction i (i = x) (m s−1)

v j :

Fluid velocity in direction j (j = y) (m s−1)

v k :

Fluid velocity in direction k (k = z) (m s−1)

v s :

Particle slip velocity (m s−1)

v p :

Absolute velocity of a particle (m s−1)

v g :

Grid velocity of a particle (m s−1)

V P :

Volume of the particle (m3)

δ :

Kroneker delta

ɛ :

Turbulence dissipation rate (m2 s−3)

µ:

Molecular viscosity of fluid (kg s m−2)

µ t :

Turbulence viscosity (kg s m−2)

µ m :

Mean value of rock particle diameter (mm)

ρ :

Particle density (kg m−3)

ρ c :

Density of continuous phase (kg m−3)

ρ f :

Fluid density (kg m−3)

σ st :

Standard deviation of rock particles’ diameters (mm)

σ k :

Prandlt number of turbulence kinetic energy

σ ε :

Prandlt number of turbulence dissipation rate

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Authors and Affiliations

  1. Korea Institute of Industrial Technology, Gyeongsan-si, South Korea

    Chang-Heon Song, Ki-Beom Kwon, Joo-Young Oh, Shinok Lee & Dae-Young Shin

  2. Korea Institute of Industrial Technology, Daegu, South Korea

    Jin-Young Park & Jung-Woo Cho

Authors
  1. Chang-Heon Song
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  2. Ki-Beom Kwon
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  3. Jin-Young Park
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  4. Joo-Young Oh
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  7. Jung-Woo Cho
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Correspondence to Jung-Woo Cho.

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Song, CH., Kwon, KB., Park, JY. et al. Optimum design of the internal flushing channel of a drill bit using RSM and CFD simulation. Int. J. Precis. Eng. Manuf. 15, 1041–1050 (2014). https://doi.org/10.1007/s12541-014-0434-6

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  • DOI: https://doi.org/10.1007/s12541-014-0434-6

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