Optimised design of downhole turbodrills with bending-torsional tilting blade

Abstract

Deep dry hot rock mining drilling operations confronts several challenges including the high-temperature conditions in the downhole environment, the unreliable performance of surface drives, and the difficult drillability of geothermal reservoir rocks. As a result, the use of downhole motors in drilling operations becomes an imperative selection. The all-metal turbodrill presently stands as the sole downhole motor capable of effectively drilling in deep wells with temperatures exceeding 180°. Although it can withstand high temperature, the output torque is small. In this study, we focus on the optimised design of the turbodrill blades with the objective of enhancing the output torque, addressing the prevailing issue of limited output torque. First, the structural parameters and parametric design are determined based on turbine blade design theory. Utilizing the quintic polynomial method, a two-dimensional blade profile is generated. Subsequently, an output torque model applicable to unsteady flow conditions is derived using the moment of momentum theorem in its integral form; Utilizing the designed blade profile, the Unigraphics NX (UG) software is used to illustrate the combination of spatial twisting, bending and tilting of the blade for the combination of the modelling method, and a three-dimensional bending-torsional tilting blade was achieved. Subsequently, numerical analysis, employing Computational Fluid Dynamics (CFD) simulation software, was conducted to examine the impact of intricate spatial modelling on the blade's flow field parameters. The optimal parameters for blade spatial modelling were ascertained to be a twist lofting radius of 63 mm, a bending angle of 30°, and an inclination angle of 3°. The blade in the hydraulic efficiency is reduced by only 2.7% of the case, the output torque increased by 18.87%, improving the performance of the turbodrill, so that the turbodrill in the geothermal development drilling has a good application prospect.