Abstract
Ultrasonic-assisted drilling (UAD) technology is a new drilling technology, which combines polycrystalline diamond compact (PDC) bits and performs better than conventional PDC drilling in improving the rock-breaking efficiency during deep hard formations. In this study, a series of simulations and laboratory tests were conducted to explore the dynamic rock-breaking mechanism of UAD with a PDC bit and the influence of different input parameters on the force and energy distribution. First, the UAD process was analyzed using a simplified drilling system model, and the relationship between the axial and tangential forces was investigated using a single PDC cutter cutting model. Then, a finite element analysis model that considers rock heterogeneity was used for the analysis. The drilling process, element damage situation, and broken form of the borehole bottom of conventional drilling (CD) and UAD were compared, and the impact of amplitude, frequency, and rotary speed on the weight on bit (WOB), torque, cutting force, and energy consumption were evaluated. Finally, laboratory experiments on PDC micro-drilling for different drilling conditions were conducted to verify the effectiveness of UAD. The results indicate that during rock-breaking using UAD, the PDC cutter periodically penetrated and broke away from the rock with ultra-high frequency, causing a large amount of damage to the rock. The frequency and amplitude significantly influenced the UAD: when the vibration frequency was between 25 and 35 kHz, the force state of the PDC cutter greatly improved compared with that of CD, and the effect of ultrasonic load reached the maximum at 33 kHz; when the amplitude was between 10 and 50 μm, WOB and torque decreased significantly and the effect of ultrasonic load improved with increase in amplitude, but the rotary speed had little effect on the torque and WOB of UAD. During the laboratory experiments, the drilling efficiency and rate of penetration (ROP) improved on using UAD. When the WOB was 100–200 N and the rotary speed was 300–400 rpm, the efficiency of ultrasonic rotary drilling to improve the ROP increased by 14.7–23.4%.
Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
