基于三维离散元方法的PDC齿冲击切削复合破岩机理研究

Research on the Composite Rock-Breaking Mechanism of PDC Cutters with Impact and Cutting Based on the Three-Dimensional Discrete Element Method

  • 摘要: 轴扭复合冲击辅助钻井技术可以有效提高PDC钻头在深层、超深层的破岩效率,但目前针对PDC齿(包含其磨损态)在复合冲击作用下轴扭冲击速度幅值与频率配比关系的研究尚不深入,导致冲击参数优化缺乏理论依据,破岩效率提升受限。为此,基于离散单元法,构建了非均质花岗岩模型,并对其在不同轴扭冲击速度幅值比、轴扭冲击频率比的PDC齿冲击切削复合作用下的动态破碎行为进行了数值模拟,并从多个方面分析了岩石的破碎特性。研究发现:在较大轴扭冲击速度幅值比和较小轴扭冲击频率比的冲击切削作用下,岩石破碎的效果更好,建议采用4∶1、2∶1 或 3∶1、1∶1 ,且在此条件下,具有一定磨损量的PDC齿会在一定程度上对岩石的破碎起促进作用,这种作用在PDC齿磨损较大时不复存在;轴向冲击速度幅值较大时,可适当增加轴向冲击频率来获得更大的岩屑体积,而轴向冲击速度幅值较小时反之;在冲击切削复合作用下,岩石以拉伸破坏为主,且70%以上的拉伸裂纹倾向于沿垂直方向扩展,其中80°以上倾角的裂纹占比达到20%。研究结果对提高深层、超深层岩石破碎效率具有一定参考价值。

     

    Abstract: The axial-torsional composite impact assisted drilling technology can effectively improve the rock fragmentation efficiency of PDC bits in deep and ultra-deep formations. However, current research on the relationship between the axial-torsional impact velocity amplitude and the frequency ratio for PDC cutters (including their worn state) under combined impact is still insufficient, leading to a lack of theoretical basis for optimizing impact parameters and limited improvement in rock-breaking efficiency. Therefore, it is necessary to conduct a systematic study on this relationship. Based on the discrete element method, a heterogeneous granite model was constructed, and numerical simulations were conducted on its dynamic fragmentation behavior under the combined action of PDC cutter impact cutting with different ratios of axial-to-torsional impact velocity amplitude and axial-to-torsional impact frequency. The rock fragmentation characteristics were analyzed from multiple aspects. The results indicate that rock fragmentation effectiveness is better under impact cutting with a larger axial-to-torsional impact velocity amplitude ratio and a smaller axial-to-torsional impact frequency ratio, and it is recommended to adopt ratios of 4:1, 2:1 or 3:1, 1:1. Furthermore, under these conditions, worn PDC cutters with a certain degree of wear can promote rock fragmentation to some extent, although this effect disappears when the wear becomes excessive. When the axial impact velocity amplitude is large, the axial impact frequency can be appropriately increased to obtain a larger cuttings volume, while the opposite approach should be taken when the axial impact velocity amplitude is small. Under the combined action of impact and cutting, rock failure is predominantly tensile in nature, with over 70% of tensile cracks tending to propagate in the vertical direction, among which cracks with dip angles exceeding 80° account for 20%. The research findings have certain value for improving rock fragmentation efficiency in deep and ultra-deep formations.

     

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