Drilling Performance Research Articles

Investigating mechanisms of debris removal in ultrasonic vibration-assisted EDM drilling

In traditional electrical discharge machining (EDM) of micro-holes, the debris removal becomes increasingly challenging as hole depth increases, significantly affecting the machining of difficult-to-machine materials. To address this issue,we first developed a micro-hole gap flow field model for a novel longitudinal–torsional ultrasonic vibration (LTV) electrode EDM drilling method. We analyzed the effects of three types of electrodes — rotation electrodes, longitudinal ultrasonic vibration (LUV) electrodes, and LTV electrodes — on the flow velocity in the micro-hole interstitial flow field. Next, we simulated the motion of fluid and debris in the interstitial flow field of micro-holes, theoretically verifying the advantage of electrode ultrasonic vibration in enhancing debris removal efficiency. Additionally, we observed the electrode tip morphology, the elemental composition on the electrode surface, and the morphology of the micro-hole inlet/outlet and inner wall to further elucidate the debris removal mechanism and confirm the superior drilling performance of the ultrasonic vibration electrodes. At an optimal ultrasonic amplitude (AL=4μm), the LUV electrode demonstrated improved consistency in the micro-hole inlet/outlet and achieved a micro-hole taper of 0.014°. The material removal rate (MRR) using the LTV electrode reached 5.14 × 105μm3/s, nearly 1.5 times higher rotation electrode. This method successfully produced a positively tapered hole suitable for injector nozzles.

The Application Potential of Artificial Intelligence and Numerical Simulation in the Research and Formulation Design of Drilling Fluid Gel Performance.

Drilling fluid is pivotal for efficient drilling. However, the gelation performance of drilling fluids is influenced by various complex factors, and traditional methods are inefficient and costly. Artificial intelligence and numerical simulation technologies have become transformative tools in various disciplines. This work reviews the application of four artificial intelligence techniques-expert systems, artificial neural networks (ANNs), support vector machines (SVMs), and genetic algorithms-and three numerical simulation techniques-computational fluid dynamics (CFD) simulations, molecular dynamics (MD) simulations, and Monte Carlo simulations-in drilling fluid design and performance optimization. It analyzes the current issues in these studies, pointing out that challenges in applying these two technologies to drilling fluid gelation performance research include difficulties in obtaining field data and overly idealized model assumptions. From the literature review, it can be estimated that 52.0% of the papers are related to ANNs. Leakage issues are the primary concern for practitioners studying drilling fluid gelation performance, accounting for over 17% of research in this area. Based on this, and in conjunction with the technical requirements of drilling fluids and the development needs of drilling intelligence theory, three development directions are proposed: (1) Emphasize feature engineering and data preprocessing to explore the application potential of interpretable artificial intelligence. (2) Establish channels for open access to data or large-scale oil and gas field databases. (3) Conduct in-depth numerical simulation research focusing on the microscopic details of the spatial network structure of drilling fluids, reducing or even eliminating data dependence.

PECVD technology deposition of high hardness a-C:H films on micro-drill surfaces: Substrate bias voltage effects

The plasma enhanced chemical vapor deposition (PECVD) technique was utilized to produce hydrogenated amorphous carbon (a-C:H) films. The overall structure of the films consists of a Cr/WC transition layer, a WC/a-C:H transition layer, and an a-C:H functional layer. The study investigated the effects of substrate bias voltages (SBVs) of −580 V, −660 V, −740 V, −820 V, and −900 V on the microstructure, mechanical, and tribological properties of a-C:H films. The findings indicate that different SBVs influence the ionic energy during the deposition of a-C:H films, consequently affecting the film growth. In this case, when the SBV is -820 V, C+ with sufficient energy will penetrate beneath the initial layer in the form of shallow injection. Therefore, compared to other experimental groups, the a-C:H films prepared under this condition have the lowest Ra value (0.42 nm), the highest sp3 CC bond content (39.88 %), the maximum hardness (31.6 GPa), the lowest friction coefficient (0.052), and the smallest wear rate (7.48 × 10−8 mm3/(N·m)), demonstrating significantly better mechanical and tribological properties. The a-C:H films, prepared at different SBVs, are deposited on micro-drill surfaces for hole drilling tests. The experimental results indicate that a-C:H films prepared at SBV of −820 V exhibit the satisfactory drilling performance due to the better mechanical and tribological properties. This is evident not only in the minimal surface wear of the film micro-drill after different drilling quantities but also by the satisfactory quality of the corresponding machined holes. The a-C:H film micro-drill prepared at SBV of −820 V exhibited larger process capability index (CPK) values for the machined holes at 500, 1000, and 2000 hole numbers of 5.449, 3.693, and 3.263 respectively. During the 2000th drill on the printed circuit board (PCB) surface, the hole wall roughness (Rz) and nail head values of the machined hole were measured to be 10.6 μm and 1.3, respectively.

ANALYSIS OF THE EFFICIENT COMPOSITION OF DRILLING FLUIDS USED IN WELLS DRILLED IN THE ABSHERON AND BAKU ARCHIPELAGOS

The article shows that the process of drilling oil and gas wells in the Absheron and Baku archipelagos is often accompanied by a number of complications. This is due to the physicochemical and lithological characteristics of the rocks in the geological section of the territory, as well as hydrogeological conditions, tectonics, and a number of other factors. A key feature of this area is the sharp change in reservoir pressure gradients along the section, along with the presence of abnormally high pore pressures in thick clayey layers. These conditions necessitate the use of carefully formulated drilling fluids to manage wellbore stability and minimize operational risks. In this study, the efficient composition of drilling fluids used in these wells is analyzed to address the challenges posed by the unique geological and geophysical conditions of the region. The investigation includes a detailed examination of the rheological properties, density, and filtration characteristics of various drilling fluid formulations. Laboratory tests and field data were utilized to determine the most effective drilling fluid composition. The aim is to identify an optimal composition that enhances drilling performance, mitigates the risks of wellbore instability, and ensures safe and effective drilling operations. The findings contribute to improving the efficiency and safety of drilling activities in the Absheron and Baku archipelagos. This research provides valuable insights into the development of customized drilling fluid solutions, highlighting the importance of adapting fluid formulations to specific geological settings. Additionally, the study emphasizes the economic benefits of optimizing drilling fluid composition, such as reducing non-productive time and lowering overall drilling costs. These insights are crucial for future exploration and production endeavors, potentially enhancing the success rate of drilling operations in similar complex geological environments. Keywords: Drilling complications, Physicochemical characteristics, Lithological characteristics, Hydrogeological conditions, Tectonics, Reservoir pressure gradients, Economic benefits, Non-productive time, Drilling costs.

Evaluating PDC bit-rock interaction models to investigate torsional vibrations in geothermal drilling

Polycrystalline diamond compact (PDC) bits are superior for drilling geothermal wells because of their superior drilling performance compared to conventional roller cone bits. However, the shear action of PDC bits generates detrimental vibrations during drilling. The main objective of this study was to establish a methodology to analyze and predict the stick-slip severity in hard rocks for geothermal wells. Two non-linear coupled axial-torsional bit-rock interaction (BRI) models are presented: one is based on a velocity-decaying friction model (VDF), and the other is based on a state-dependent delay friction model (SDDF). The capabilities of the two models were evaluated to assess the axial and torsional dynamic stabilities of drill stems in deep geothermal wells. The comparative analysis, along with the results from both models, were validated using geothermal well downhole data. Five distinct zones were selected for analysis, and the stick-slip severity value (SSV) was calculated using these two models (VDF and SDDF). The results from these two models for the five different zones were compared with the field data. The results indicated that VDF demonstrated superior quality when compared with field values, as the results of VDF were within the interquartile range of the observed SSV in each zone. A sensitivity analysis employing spider plots was performed for both models, considering parameters related to rock, bit, operational, and frictional aspects. In terms of the operational parameters, the weight-on-bit (WOB) and revolutions per minute (RPM) exerted the most significant influence on the SSV for both models. For the VDF model, the sensitivity analysis indicated that the frictional parameter, uniaxial compressive strength (UCS), and number of cutters (NOC) had the most pronounced impact on the SSV. In the case of the SDDF, the Intrinsic specific energy (ISE), bit diameter, and number of blades (NOB) are the key factors that predominantly affect the SSV.

Research on cryogenic high-speed drilling performance of metal matrix composite materials (Al/SiC) using cryogenically treated drills

Research on cryogenic high-speed drilling performance of metal matrix composite materials (Al/SiC) using cryogenically treated drills

Effect of solid lubricant reinforcing on drilling performance of castamide and thermal analysis

AbstractThis study addresses the pressing need for enhancing the machining performance and hole quality of castamide by investigating the effects of solid lubricant addition and drilling parameters. Castamide, a highly crystalline polyamide synthesized via anionic ring‐opening polymerization, offers superior mechanical, physical, and chemical properties compared to conventional polyamide 6. However, its machining process, particularly drilling, remains a critical challenge due to its viscoelastic nature and sensitivity to heat generation. Using experimental investigations, thrust forces, drilling temperatures, hole geometry, and quality parameters are systematically analyzed and discussed. Notably, the study introduces Kestlub, a modified version of castamide with solid lubricant, and evaluates its drilling performance, a previously unexplored area in the literature. The research employs response surface methodology to model experimental data, considering both linear and quadratic effects of drilling parameters. Additionally, the significance of each parameter is assessed using ANOVA tables and Pareto charts, offering valuable insights into optimizing the drilling process for enhanced hole quality in castamide. It found that optimal drilling conditions occur at low rotational speeds and high feed rates, but thermal damage, influenced by factors like thermal conductivity and transition temperature, affects hole geometry and burr formation.Highlights Drilling performances of solid lubricant reinforced castamides were investigated. Drilling temperatures were recorded with a thermal camera and differential scanning calorimeter and thermal gravimetric analyses were performed. Drilling properties were analyzed statistically according to the response surface method. It found that optimal drilling conditions occur at low rotational speeds and high feed rates.

Evaluation of using micronized saudi calcite in ilmenite-weighted water-based drilling fluid

A high-density water-based drilling fluid (WBDF) is crucial for maintaining wellbore stability, controlling formation pressures, and optimizing drilling performance in challenging subsurface conditions. In the present research, the effect of micronized calcium carbonate (calcite), extracted from the Aruma formation outcrop, is evaluated as one of the additives that could be added to the ilmenite-weighted WBDF to enhance and optimize its properties. Various concentrations of Calcite microparticles were introduced into identical fluid formulations to assess their impact. The concentrations ranged from 0, 10, 20, to 30 lb/bbl, providing a comprehensive examination of the effects of calcite microparticles across a spectrum of concentrations within the fluid. The results highlighted that adding Barite microparticles to the WBDF revealed a notable enhancement in rheological properties. Specifically, the yield point demonstrated an increase of 37%, 37%, and 11% for concentrations of 10, 20, and 30 lb/bbl of calcite, respectively. Equally significant, high-pressure-high-temperature (HPHT) filtration analysis indicated a considerable enhancement for the fluids containing calcite microparticles. A reduction of 14.5%, 24.6%, and 13% were observed in HPHT filtrate for concentrations of 10 lb/bbl, 20 lb/bbl, and 30 lb/bbl respectively. Simultaneously, there is a reduction in filter cake thickness by 20%, 40%, and 20%, respectively. No ilmenite settling was observed in the sample containing 20 lb/bbl of calcite, unlike the other concentrations. These diverse results strongly suggest that the optimal concentration for calcite microparticles is 20 lb/bbl. The combined utilization of the optimal concentration of calcite microparticles alongside the established additives proves to be an effective strategy for optimizing the ilmenite-weighted WBDF performance in terms of both thermal stability and rheological behavior.

Influence of clean cooling medium on the hard drilling performance and machined surface integrity of 42CrMo steel

42CrMo ultra-high strength steel has high strength and fracture toughness, which is widely used in key components, such as gears, connecting rods and molds. This type of workpiece material, especially after quenching and hardening treatment, still has prominent issues with hole machining. In this work, the clean cutting media, including dry, cold air and liquid nitrogen (LN2), are selected to investigate the hard drilling performance and machined surface integrity of 42CrMo steel. The feasibility of extending tool life and improving hole machining quality is explored through clean cooling medium. The cutting force and cutting temperature are lower under cold air and LN2 conditions than that under dry cutting conditions. The tool life is extended under cold air and LN2 conditions. The low temperature brought by LN2 promotes the transformation from folded to lamellar for chip free surface. The degree of chip curling becomes larger and easier to break and discharge, which reduces the unfavorable effects of chip clogging. The thermal damage phenomenon on the hole wall surface is disappeared. The surface roughness is reduced by 37.3%, and the maximum microhardness is increased by 6.6%, which significantly improves the machined surface integrity of holes. This work demonstrates the feasibility of improving the machinability of harnessed ultra-high strength steel by LN2 cooling.

An Experimental Study to Assessing the Efficacy of Oil to Prevent Differential Stuck Pipe Incidents in Zubair Oil Field, Southern Iraq

This study focuses on the important role of drilling mud in successful drilling operations, particularly in preventing and treating differential stuck pipes. Differential pipe sticking (DSP) is a common challenge when drilling through a pay zone with water-based drilling mud containing bentonite clay. However, using oil as an additive in a water-based mud (WBM) system offers distinct advantages and can significantly improve drilling performance. The research utilizes the Fann VG meter, a self-fabricated tester, and a tester of stickance to investigate the impact of oil on water-based drilling mud (WBM) and controlling DSP to address this challenge. The empirical study demonstrates that adding oil to the drilling fluid enables it to maintain its rheological properties (PV, YP, and API fluid loss) while reducing filtration loss from 7 to 4.8 cc and friction coefficient from 0.30 to 0.05. This indicates that emulsion mud can mitigate the risks of differential sticking by maintaining the oil concentration within the recommended limit (not exceeding 3%). Balancing the maintenance of rheological properties with the reduction of friction coefficient is essential to reaching optimal drilling performance and preventing differential pipe sticking.

Enhancing Interpretability in Drill Bit Wear Analysis through Explainable Artificial Intelligence: A Grad-CAM Approach

This study introduces a novel method for analyzing vibration data related to drill bit failure. Our approach combines explainable artificial intelligence (XAI) with convolutional neural networks (CNNs). Conventional signal analysis methods, such as fast Fourier transform (FFT) and wavelet transform (WT), require extensive knowledge of drilling equipment specifications, which limits their adaptability to different conditions. In contrast, our method leverages XAI algorithms applied to CNNs to directly identify fault signatures from vibration signals. The signals are transformed into their frequency components and then employed as inputs to a CNN model, which is trained to detect patterns indicative of drill bit failure. XAI algorithms are then employed to generate attention maps, highlighting regions of interest in the CNN. By scrutinizing these maps, engineers can identify critical frequencies associated with drill bit failure, providing valuable insights for maintenance and optimization. This method offers a transparent and interpretable framework for analyzing vibration data, enabling informed decision-making and proactive maintenance strategies to enhance drilling efficiency and minimize downtime. The integration of XAI with CNNs facilitates a deeper understanding of the root causes of drill bit failure and improves overall drilling performance.

ДИСПЕРГАТОРЫ ДЛЯ БУРОВЫХ РАСТВОРОВ

Dispersants used in drilling technology to improve the technological performance of drilling and grouting solutions are considered. The comparative characteristics of the devices are given, their ad-vantages and disadvantages are listed

Ultrafast processing of zirconia ceramics by transient and selective laser absorption

Ultrashort-pulse lasers (USPLs) are used in the machining of zirconia ceramics (ZrO2) because of their extremely high peak intensities. However, highly efficient and high precision microprocessing of ZrO2 remains challenging. In this study, we applied a transient and selective laser (TSL) processing technique by combining a USPL and a continuous-wave (CW) laser to realize ultrafast drilling of opaque ZrO2. Ultra-high-efficiency TSL drilling of ZrO2 was achieved with a processing efficiency 1800 times higher than that of USPL drilling. The material removal mechanism, hole formation process, and parameter dependence of TSL drilling were revealed by direct observation of the internal processing phenomenon on a timescale of microseconds. The variations in the processed surface characteristics, including surface morphology, elemental composition, and phase composition, are also presented. Subsequently, the effect of different excited electron regions occurring in the picosecond timescale induced by the USPL on the TSL drilling performance is discussed. Finally, the repeatability and stability of the TSL processing were verified by fabricating microarrays of different sizes. This study will contribute to revealing the ultrafast processing mechanisms of TSL processing in ZrO2 microfabrication. Furthermore, this technique can significantly broaden the applications of ZrO2 in the advanced electronic industry by greatly improving the microprocessing efficiency.

Deep Learning Method for Improving Rate of Penetration Prediction in Drilling

Summary The urgent global need to reduce CO2 emissions necessitates the development of sustainable power generation sources. Geothermal power emerges as a renewable and dependable energy option, harnessing the Earth’s natural heat sources for electricity generation. Unlike other renewables, geothermal energy offers uninterrupted power, immune to weather conditions. However, its efficiency hinges on technological innovation, particularly in the challenging realm of geothermal drilling. Rate of penetration (ROP) is a crucial drilling performance metric, and this study explores how deep learning models, particularly transformers, can optimize ROP prediction. Leveraging data from Utah Frontier Observatory for Research in Geothermal Energy (FORGE), we analyze the relationship between drilling parameters and ROP. Traditional drilling optimization methods face limitations, as drilling dysfunctions can disrupt the linear relationship between ROP and weight on bit (WOB). We propose a dynamic approach that allows adapting drilling parameters in real time to optimize ROP. Our experiments investigate optimal sampling intervals and forecast horizons for ROP prediction. We find that a 60-second sampling interval maximizes the transformer model’s forecasting accuracy. Additionally, we explore retraining to fine-tune models for specific wells, improving forecasting performance. Our transformer-based ROP forecaster outperforms deep learning models, achieving a low overall 5.22% symmetrical mean average percentage error (SMAPE) over a forecast horizon of 10 minutes. This model offers opportunities for cost-effective drilling optimization, with real-time accuracy, speed, and scalability. Future work will focus on larger data sets and integration with drilling automation systems to further enhance the model’s practicality and effectiveness in the field.

Investigation of the effect of ultrasonic vibration on the performance of the friction drilling by FEM simulation

The friction drilling process is very important in various industries such as automotive, aerospace, and oil and gas industries. Therefore, they have always sought to find methods to improve this process. One of these methods is to optimize the application of ultrasonic vibrations in the process, and limited research has been done in this regard. The current research aims to investigate the effect of ultrasonic vibrations simultaneously with the parameters of drilling on the friction drilling process to optimize this process with the help of finite element simulation. Due to the nature of the complex transformations of the process, a Coupled Eulerian–Lagrangian model of the process was first created in the Abaqus software. Then, the process simulation was carried out in the presence and absence of ultrasonic vibrations. Rotational speed, feed rate, and amplitude of vibrations are the influencing parameters, and sheet temperature and axial force, and torque applied to the tool are the parameters investigated in this research. The results show that higher rotation speed and lower feed rate lead to a reduction of axial force and torque. Also, the application of ultrasonic vibration reduces up to 50.48% the axial force and up to 46.67% torque, and this reduction is improved by increasing the range of vibrations. The optimal mode was selected After analyzing 12 different modes based on the lowest amount of axial force and torque on the pin. It was found that the ideal mode occurs at a feed rate of 4.23 m/s and a rotation speed of 3000 rpm, with a 20-µm range. These findings and optimizing drilling parameters bring new horizons in material bonding techniques in various industries.

Construction of coal pitch-based HA-K grafted poly condensates and their excellent anti-temperature and viscosity-reducing properties

Humic acids (HAs) are widely used as filtrate and viscosity reducers in drilling fluids. However, their practical utility is limited due to poor stability in salt resistance and high-temperature resistance. High-temperature coal pitch (CP) is a by-product from coal pyrolysis above 650 °C. The substance's molecular structure is characterized by a dense arrangement of aromatic hydrocarbon and alkyl substituents. This unique structure gives it unique chemical properties and excellent drilling performance, surpassing traditional humic acids in drilling operations. Potassium humate is prepared from CP (CP-HA-K) by thermal catalysis. A new type of high-quality humic acid temperature-resistant viscosity-reducer (Graft CP-HA-K polymer) is synthesized with CP-HA-K, hydrolyzed polyacrylonitrile sodium salt (Na-HPAN), urea, formaldehyde, phenol and acrylamide (AAM) as raw materials. The experimental results demonstrate that the most favorable conditions for the catalytic preparation of CP-HA-K are 1 wt% catalyst dosage, 30 wt% KOH dosage, a reaction temperature of 250 °C, and a reaction time of 2 h, resulting in a maximum yield of CP-HA-K of 39.58%. The temperature resistance of the Graft CP-HA-K polymer is measured to be 177.39 °C, which is 55.39 °C higher than that of commercial HA-K. This is due to the abundant presence of amide, hydroxyl, and amine functional groups in the Graft CP-HA-K polymer, which increase the length of the carbon chains, enhance the electrostatic repulsion on the surface of solid particles. After being aged to 120 °C for a specified duration, the Graft CP-HA-K polymer demonstrates significantly higher viscosity reduction (42.12%) compared to commercial HA-K (C-HA-K). Furthermore, the Graft CP-HA-K polymer can tolerate a high salt concentration of 8000 mg·L−1, measured after the addition of optimum amount of 3 wt% Graft CP-HA-K polymer. The action mechanism of Graft CP-HA-K polymer on high-temperature drilling fluid is that the Graft CP-HA-K polymer can increase the repulsive force between solid particles and disrupt bentonite's reticulation structure. Overall, this research provides novelty insights into the synthesis of artificial humic acid materials and the development of temperature-resistant viscosity reducers, offering a new avenue for the utilization of CP resources.

Experimental study on step drill geometry and pecking drilling with variable parameters processing method as drilling of CFRP and Ti stacks

Integrated drilling of CFRP and Ti stacks is a challenging task due to the disparate machining property. Choosing proper tool structure and processing method are effective ways to obtain high-quality holes. In this paper, drilling experiments are carried out to research the performance of step drills and variable processing method in drilling of CFRP/Ti stacks. The effect of ratio of primary cutting edge diameter, point angle of primary cutting edge and secondary cutting edge and the location of variable processing on the burr of Ti layer, delamination and thermal damage are analyzed. Decrease the primary cutting edge can restrain the thermal damage and delamination. The point angle of secondary cutting edge has the influence on the final holes directly, and as drilling from Ti to CFRP, the point angle of secondary cutting edge is 110°, by contrast, as drilling from CFRP to Ti, the point angle of secondary cutting edge is 130°. Pecking drilling with variable parameter can reduce the drilling damage. As the pecking drilling feed rate increase from 2f to continuously drilling, thermal damage increases by 176.4 %. Variable parameter processing method can reduce the thermal damage as drilling of Ti layer with low spindle speed.

Polymer-laponite composites as filtrate reducer for high temperature and salt resistant drilling fluid: Characterization and performance evaluation

In deep and ultra-deep well drilling, ultra-high temperatures and high salt lead to poor drilling fluid performance. In this study, N, N-dimethylacrylamide (DMAA), dimethyldiallylammonium chloride (DMDAAC), 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS), 4-acryloylmorpholine (ACMO) and modified laponite (m-LAP) were polymerized into polymer nanocomposites PDADA-LAP by free radical polymerization in aqueous solution. The structure of PDADA-LAP was characterized by FT-IR, 1H NMR and XPS. The microstructure of PDADA-LAP was characterized by TEM, SEM and EDS. The results showed that LAP improved the network structure of the polymer by hydrogen bonding and covalent bonding. The effect of temperature on the degradation of the polymer solution was investigated. The experiment showed that the degradation temperatures of the polymer was 220 °C. PDADA-LAP was used as a filtrate reducer in drilling fluids. The results showed that 3.0 wt% PDADA-LAP could improve the filtration performance of drilling fluids at high temperature of 220 °C and resist contamination with 20 wt% NaCl. The FLAPI and FLHTHP were 7.0 mL and 28.6 mL, respectively. PDADA-LAP is adsorbed on bentonite particles through hydrogen bonding and electrostatic interaction, which slows down the contamination of bentonite particles by NaCl and gives the drilling fluid a good effect to reduce fluid loss at high temperature and high salt.

Drilling performance of micro-textured twist drill bit for TI-6AL-4V alloy: Validated FEM and statistical approaches

The titanium alloy, particularly Ti-6Al-4V, is an extensively demanded material in diverse sectors because of its superior physical and chemical properties. Nevertheless, the inherent hardness of the material causes challenges during machining operations. The alloy's heat-resistance characteristic induces increased friction and heat generation on cutting tools, ultimately causing a decrease in the tool life. In an attempt to overcome this issue, numerous forms of surface texturing have been investigated with the aim of improving the tribological characteristics of the material. The aim of the present investigation was to enhance the cutting performance of drill bits by implementing micro-textured patterns, hence minimizing thrust force, torque, and tool temperature. The combined effect of three distinct micro-textured geometries on a drill bit's flank, flute, and margin surfaces, with the influence of coating conditions, on the performance of drilling operations was investigated. The Finite Element Method (FEM) was used to perform a range of varied drilling operations. The Grey Relation Analysis (GRA) and General Linear Model (GLM) were employed to assess and compare the drilling performances with respect to thrust force, torque, and drill bit temperature. It was found that the square-sectioned textures on the side face exhibited the most obvious influence on the drilling performance. In the meantime, the textures found on the flute face were identified as having a comparatively smaller influence. The ideal configuration for the drill bit entailed a flank face with a square sectioned texture, a flute face without any texture, a margin face with a square sectioned texture, and a hard coating. As a result, the current situation substantially reduced cutting forces, tool wear, and tool temperature by 51 %, 20.5 %, and 23.4 % compared to the drilling condition without textured drill bits.

Optimization of AWJ parameters for improved material removal and hole geometry in drilling of Glass Fiber/Aluminum mesh epoxy hybrid composites

AbstractThis study explores the application of abrasive waterjet drilling (AWJD) for varied patterns of GF/Al mesh hybrid composites (neat glass NG, AG: Al in the exterior surface, and GA: Al in the center). Key parameters such as jet pressure (P), standoff distance (S), and traverse speed (V) are systematically varied, influencing material removal rate (MRR), hole taper ratio (), and roundness error (). Employing a Taguchi approach with an L9 design. It was indicated that the optimal conditions for maximum MRR are (P: 150 MPa, S: 2 mm, and V: 900 mm/min). V and S are the main influential parameters on and . Gray relational analysis (GRA) is employed for simultaneous optimization, enhancing drilling performance. The optimal parameters P of 150 MPa, S of 2 mm, and V of 300 mm/min are determined. Validation trials confirm the effectiveness of the determined parameters. A robust multiple regression equation is formulated, providing a predictive model that aligns closely with experimental observations.Highlights The hybrid composites were drilled via a nontraditional process. The attributes of the hole geometry and the material removal impacts were studied. Operation parameters were optimized to improve MRR, , and . A multiple regression model and a confirmation test were performed and validated.