Design and study of special-shaped PDC cutter for hard sandstone strata of Shaximiao Formation

doi:10.3785/j.issn.1006-754X.2025.04.160

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (2): 262-271 DOI: 10.3785/j.issn.1006-754X.2025.04.160

Optimization Design

Design and study of special-shaped PDC cutter for hard sandstone strata of Shaximiao Formation

Yachao MA¹(

),Yifei LUO¹,Zhun RONG²,Lei TAO³,Huichuan ZENG²,Dong JIANG²,Wenyuan ZHANG³

^1.School of Mechatronic Engineering, Southwest Petroleum University, Chengdu 610500, China
^2.Northeast Sichuan Gas Mine, Petro China Southwest Oil and Gasfield Company, Dazhou 635000, China
^3.Engineering Technology Research Institute, CNPC Xibu Drilling Engineering Company Limited, Urumqi 830063, China

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Abstract

To address the issues of low mechanical drilling speed, severe wear, and high drilling costs of PDC (polycrystalline diamond compact) bits in the hard sandstone strata of the Shaximiao Formation in eastern Sichuan, a comprehensive study was conducted on the rock-breaking performance of special-shaped PDC cutters in the Shaximiao Formation hard sandstone strata. Aiming at the high abrasiveness and hard-plastic characteristics of the sandstone strata in Shaximiao Formation, four types of special-shaped PDC cutters were designed, including axe-shaped cutter, circular-arc curved-surface cutter, axe-shaped curved-surface cutter, and inclined axe-shaped cutter, and a comprehensive rock-breaking specific energy evaluation method combining PDC cutter breaking rock by cutting and pressing was established. Then, using the rock-breaking simulation model, the optimization design for structural parameters of these special-shaped PDC cutters was conducted, and the rock-breaking performance of the optimized PDC cutters was simulated and analyzed. The results showed that the axe-shaped cutter with a blade angle of 130° and the circular-arc curved-surface cutter with a arc radius of 25 mm had the lowest comprehensive rock-breaking specific energy. The final determined arc radius and blade angle of the axe-shaped curved-surface cutter was 25 mm and 130°, and the blade angle and inclination angle of the inclined axe-shaped cutter was 130° and 70°. Four types of special-shaped PDC cutters exhibited significantly lower comprehensive rock-breaking specific energy and blade temperature compared to conventional PDC cutters, with a clear positive correlation between comprehensive rock-breaking specific energy and wear height. The laboratory rock-breaking test results indicated that the axe-shaped cutter and the axe-shaped curved-surface cutter had superior rock-breaking performance. The research results provide a theoretical foundation for the customized design of PDC bits tailored for the hard sandstone strata of the Shaximiao Formation.

Key words： hard sandstone of Shaximiao Formation special-shaped PDC cutter rock-breaking specific energy rock-breaking performance

Received: 24 July 2024 Published: 06 May 2025

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	Yachao MA
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	Zhun RONG
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	Huichuan ZENG
	Dong JIANG
	Wenyuan ZHANG

Cite this article:

Yachao MA,Yifei LUO,Zhun RONG,Lei TAO,Huichuan ZENG,Dong JIANG,Wenyuan ZHANG. Design and study of special-shaped PDC cutter for hard sandstone strata of Shaximiao Formation. Chinese Journal of Engineering Design, 2025, 32(2): 262-271.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.04.160 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I2/262

沙溪庙组硬质砂岩地层异形PDC齿的设计与研究

为解决川东沙溪庙组硬质砂岩地层PDC（polycrystalline diamond compact，聚晶金刚石复合片）钻头机械钻速低、磨损严重及钻井成本高的问题，对异形PDC齿在沙溪庙组硬质砂岩地层的破岩性能进行了综合研究。针对沙溪庙组砂岩地层高研磨性、硬塑性的特点，设计了斧形齿、圆弧曲面齿、斧形曲面齿和斜斧形齿等4种异形PDC齿，并建立了PDC齿切削与压入破岩结合的综合破岩比功评价方法。随后，利用破岩仿真模型，开展了异形PDC齿结构参数优化设计，并对优化后的异形PDC齿进行了破岩性能仿真分析。结果表明：齿刃角为130°的斧形齿和圆弧半径为25 mm的圆弧曲面齿的综合破岩比功最小。最终确定斧形曲面齿的圆弧半径为25 mm，齿刃角为130°，斜斧形齿的齿刃角为130°，倾斜角度为70°。4种异形PDC齿的综合破岩比功和齿刃温度均低于常规PDC齿，且综合破岩比功与磨损高度呈正相关。室内破岩试验结果表明，斧形齿与斧形曲面齿具有更优异的破岩性能。研究结果为沙溪庙组硬质砂岩地层的个性化PDC钻头设计提供了理论基础。

关键词： 沙溪庙组硬质砂岩, 异形PDC齿, 破岩比功, 破岩性能

Fig.1 Special-shaped PDC cutters

Fig.2 Cutting-based rock-breaking simulation model of PDC cutter

Fig.3 Indentation-based rock-breaking simulation model of PDC cutter

Table 1 Material parameters of PDC cutter and sandstone of Shaximiao Formation

Table 2 Mesh type and number of rock-breaking simulation model for PDC cutter

Fig.4 Axe-shaped cutters with different blade angles

Fig.5 Comparison of comprehensive rock-breaking specific energy of axe-shaped cutters with different blade angles

Fig.6 Circular-arc curved-surface cutters with different arc radii

Fig.7 Comparison of comprehensive rock-breaking specific energy of circular-arc curved-surface cutters with different arc radii

Fig.8 Tooth structure of axe-shaped curved-surface cutter

Fig.9 Tooth structure of inclined axe-shaped cutter

Fig.10 Stress field of special-shaped PDC cutters for rock-breaking

Fig.11 Comparison of rock-breaking specific energy of PDC cutters during cutting

Fig.12 Comparison of rock-breaking force of PDC cutters during indentation

Fig.13 Comparison of rock-breaking specific energy of PDC cutters during indentation

Fig.14 Comparison of comprehensive rock-breaking specific energy of PDC cutters

Fig.15 Peak blade temperature of PDC cutters

Fig.16 Comparison of comprehensive rock-breaking specific energy of PDC cutters with wear height of 0-3 mm

Fig.17 Comparison of fitting results between comprehensive rock-breaking specific energy and wear height of PDC cutters

Fig.18 PDC cutters for test

Fig.19 Cutting test device of PDC cutter

Fig.20 Comparison of rock debris produced by PDC cutters cutting and breaking rock

Table 3 Comparison of wear amounts of PDC cutters

Fig.21 Comparison of average cutting force of PDC cutters


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