Drilling Process Research Articles

Design of Mold Flipper in an Effort to Improve The Efficiency of Mold Maintenance Process

Molding is a production process by forming raw materials using a rigid frame or model used in the manufacturing industry to mold materials called a mold. Injection molding is a technique in the manufacturing industry for molding thermoplastic materials. Thermoplasctic materials commonly molded with Injection Molding techniques are Polystyrene, Acrylonitrile Butadiene Styrene (ABS), PMMA (Polymethyl Methacrylatic) and others. The purpose of this research is to design and build a flipper molding tool for an easier and more efficient mold maintenance process. This research uses descriptive methods. Data is taken through direct observation and through reference books both from companies and websites and journals related to the report material. The data obtained was analyzed using descriptive analysis. it is found that the material used in the work is Carbon Steel (S45C). The process of making Flipper Clamps Mold has several stages, namely the Design Making Process, Material Selection Process, Cutting Process, Milling Process, Grinding Process, Drilling Process, Welding Process, and Assembly Process. With this Flipper Clamping tool, it is hoped that it can make it easier for operators to maintain and repair molds, because the previous mechanism requires two operators to flip molds that weigh more than 200 kg, now they only need to flip by turning the lever of this tool.

Fabrication of customized microneedle with high 3D capability and high structural precision

Advanced 3D fabrication techniques are essential for the processing of 3D devices, which mainly focusing on excellent 3D fabrication capability and high structural precision. Although 3D printing technology allows for the creation of complex 3D structures with extensive customization, it faces notable challenges in achieving precise micro/nanostructures within materials due to incomplete resin curing bonds. Here, we propose integrating projection micro-stereolithography (PμSL) with femtosecond (fs) laser Bessel beam drilling to create 3D structures with advanced customization, precise structures (including size accuracy and aspect ratio), and efficient processing. Starting with the drilling process using Bessel beams, we have achieved micro-holes with a diameter of approximately 1μm and the aspect ratio reached 1017:1 on 3D printed items by regulating the transparency and elasticity of the products. Furthermore, we have applied this technology to produce tailor-made microneedles, including slanted-tip microneedles and porous microneedles, demonstrating its ability for extensive, efficient micro-hole processing with a peak drilling speed of 200,000 holes per second. This technology offers an innovative approach to creating three-dimensional devices with intricate cavity structures, and its impressive processing capabilities suggest potential for broad industrial implementation.

Optimizing the drilling process parameters of AZ91 based hybrid composites using TOPSIS and grey relational analysis

AZ91 is a popular magnesium alloy that contains aluminum (Al), zinc (Zn), and small amounts of other elements that offers a good balance of mechanical properties and corrosion resistance, making it suitable for various applications such as automotive, aerospace, sports, and biomedical. The current research works focused on optimizing drilling process parameters such as cutting speed, feed rate, a set of standard tools, and biofriendly coolants against the surface roughness and axial thrust force for AZ91/ nano hBN/ micron TiB2 hybrid composites. Taguchi L18 orthogonal array was used to design the drilling experiments. The axial thrust force and surface roughness of the drilled hole were observed as response of the experiments. Based on the results from TOPSIS and GRA, the optimal conditions were determined to be a spindle speed of 65 m/min, feed rate of 1 mm/rev, using a High-Speed Steel (HSS) tool, and Liquid Nitrogen (LN) coolant for 1 wt% of nano hBN in the hybrid composite. These parameters resulted in the lowest axial thrust force and surface roughness, highlighting their effectiveness in optimizing the drilling performance of AZ91/TiB2/hBN composites.

Modifying the Effects around the Well can have an Impact on the Drilling Process

Environmental changes around a well can significantly affect the drilling process. This paper examines the effects of flow rate, bottomhole pressure, sheet permeability, viscosity, pressure gradient and well radius on the drilling process. It is shown that the energy-dynamic instability of the sheet’s near-shiva space, a highly active region in the formation, leads to changes in reservoir rock and fluid properties during the drilling process. These changes include physicochemical transformations such as deposition of asphaltenes, paraffins, and resins, as well as swelling of clay particles, which can disrupt reservoir physical properties and affect hydrocarbon flow. In addition, completion and production techniques and the chemistry of drilling and pressure fluids are particularly critical for low-permeability reservoirs. In this paper, the concept of skin effect is also introduced to assess the impact of process fluids on the bottomhole region, and a new assessment model is proposed. The results of the study are important for improving drilling technology and optimising reservoir development.

Abrasive waterjet drilling process enhancement using machine learning and evolutionary algorithms

ABSTRACT To improve the abrasive waterjet drilling procedure for yttrium-stabilized zirconia-coated Inconel 718 superalloy, this study suggests an integrated approach using machine learning and an evolutionary algorithm. The objective is to simultaneously minimize the erosion diameter and taper angle of the drilled holes by identifying the best combination of drilling parameters such as stand-off distance, abrasive flow rate, waterjet pressure, and angle of impact. The machine learning models are developed using the random forest algorithm after tuning its hyperparameters to predict the erosion diameter and taper angle. The multi-verse optimization (MVO) algorithm is used to identify the best combination of drilling parameters. The comparison of results proved the efficacy of MVO over other algorithms. Confirmation experiment results are also in line with the results of MVO, since the percentage of deviation is meager. This integrative approach has the capability of significantly improving aerospace and industrial abrasive waterjet drilling operations.

A LESO Based Backstepping Controller Considering Coal Seam Hardness for Rotary Speed in Coal Mine Tunnel Drilling Process

A LESO Based Backstepping Controller Considering Coal Seam Hardness for Rotary Speed in Coal Mine Tunnel Drilling Process

Improved Rheological Properties and Lubricity of Drilling Fluids at Extreme Temperatures and Pressures Using Graphene Oxide and Flowzan

Summary The use of graphene-based lubricants in water-based drilling fluids (WDFs) has emerged as a promising avenue for enhancing their tribological properties, particularly under high-temperature (HT) conditions, by incorporating inorganic-material-based additives. For this study, we used a green and adsorption-based approach to prepare highly-dispersed graphite for modification, utilizing a cationic surfactant. Our research demonstrated the effective dispersion of the prepared graphite in water, characterized by low sedimentation rates and small contact angles in distilled water. The concentration dosage of Flowzan® on graphite was determined to be 0.02 g/g. To assess the effectiveness of modified graphite as a lubricating additive in water-based drilling, we conducted rheological studies and measured viscosity coefficients. The results revealed a significant decrease in the viscosity coefficient of the drilling fluid by 68% at 300°F when incorporating 0.05% modified graphene. Furthermore, the study investigated the thickness of six WDFs under high-temperature, high-pressure (HTHP) conditions. The addition of 3% graphene expansion resulted in a notable reduction in the volume of HTHP liquid filtrate by up to 30% compared with the control. These experimental findings underscore the advantageous effects of nanoparticle addition on properties such as lubricity, rheology, fluid loss, and thermal stability, potentially revolutionizing the drilling process. In addition to evaluating the performance of modified graphite, we analyzed its primary, crystalline, and morphological properties using various techniques, including particle size tests, zeta potential tests, Fourier transform infrared (FTIR), powder X-ray diffraction (XRD), and scanning electron microscopy (SEM). These analyses elucidated the lubrication mechanism, demonstrating that graphite modification primarily occurred through physical adsorption without altering the crystal structure. These insights provide valuable guidance for the development of high-performance WDFs tailored to endure the challenges of drilling operations.

Application of Central Composite Design in the Drilling Process of Carbon Fiber-Reinforced Polymer Composite

Composite materials are utilized in various industries due to their advantageous properties. Drilling is a crucial process for joining these materials to construct the structures. During the drilling of composite materials, several types of defect can occur, with delamination being the most prevalent. Delamination adversely effects the properties of the drilled hole and diminishes the quality of the final structure. Thrust force is a key parameter used to monitor the drilling process; a higher thrust force increases the likelihood of defects, particularly delamination, in the drilled area. In this article, a central composite design is applied to the drilling process of carbon fiber-reinforced polymer (CFRP) composites, focusing on parameters such as rotational speed, feed rate, and the angle between the composite layer sequences. The objective is to minimize delamination factors and thrust force. The effect of drilling parameters on the responses is analyzed independently. The results indicate that the derived models can predict the thrust force and delamination factors in the drilling of CFRP composites.

Skin Factor Test Experiment of the Combined Structure of Blind and Screen Pipes

During the drilling process of horizontal wells in offshore oil fields, when encountering highly clayey shale or sandy shale sections, a common practice is to use a combination of blank pipes and screen pipes in the completion column to isolate high clay content layers. This helps prevent significant clay blockage in the screen pipes or wellbore, thereby reducing production loss. However, when blank pipes cannot effectively isolate clayey or sandy shale sections, the migration of clay content can lead to screen pipe blockage, adversely affecting production capacity. Given the current lack of evaluation methods for the impact of combined blank and screen pipe completion columns on production capacity, an experiment was designed to evaluate the skin factor of the completion column with a combination of blank and screen pipes. Through the calculation of the skin factor, the variation patterns of the skin factor for completion columns with blank and screen pipes under different conditions were obtained. These findings were then applied to a production evaluation. The research results revealed the following: (1) As the proportion of blind pipes increases, the skin factor of the combination of blind pipes and screen pipes in the completion tubing also increases. Excessive blind pipe ratios reduce production capacity. (2) In cases where the annular space is not completely filled, the influence of the blind pipe proportion on production capacity can be negligible. However, when the annular space is 100% filled, a higher proportion of blind pipes and silt content results in a larger skin factor, which leads to reduced production. In the application of the XH horizontal well case study, using the calculated model for the skin factor of the combination of blind pipes and screen pipes in the completion tubing established in this paper, it was determined that when the annular space was not completely blocked and 20 m of blind pipes were not placed in the designated position, the impact on the production index was 0.73%. However, when the blind pipes were not placed in the designated position for 100 m, the impact on the production index reached 1.47%. The method developed in this paper provides theoretical guidance for the optimization of completion tubing in mudstone and sandy mudstone sections and for production evaluation.

Modeling and verification of cortical bone drilling forces based on tissue structure heterogeneity

Bone drilling mechanism study is the basis for the optimization of cortical bone drilling process and drill geometry. In this paper, a drilling force model for modified drills with thinned chisel edge is established considering the heterogeneous structure of cortical bone. The bone mineral density is embedded into the established model, the model can predict the axial thrust force change along the drilling depth direction, and the model is verified through cortical bone drilling experiments. The thrust force and torque predicted by the model are in good agreement with the drilling experimental results of cortical bone drilling. Then, the drilling performance of the modified drill and the common drill is compared through cortical bone drilling experiments. Compared with common drill bits, the maximum reduction in average thrust force of the modified drill bit during stable drilling is 21.21 % (n = 2500 rpm, Vf=60 mm/min). The maximum reduction in average roughness of the hole wall is 21.87 % (n = 500 rpm, Vf=10 mm/min). The drill chisel edge thinning design reduces the negative impact of the negative normal rake angle on the cutting lip of common drill on drilling force and stability. Therefore, the drill bit chisel edge thinning design can effectively improve the drilling performance.

A smart look at monitoring while drilling (MWD) and optimizing using acoustic emission technique (AET)

Monitoring while drilling (MWD) is a crucial task in mining operations. Accurately measuring drill and rock-related operating parameters can significantly reduce the cost of drilling operations. This study explores the potential of monitoring drilling specific energy (SE) and optimizing drilling operations by processing vibroacoustic signals generated while drilling. For this purpose, 30 samples of different rocks, are used for drilling tests. During the drilling process, the acoustic and vibration signals are recorded and analyzed in the time, frequency, and time–frequency domains., and parameters related to the resulting spectra are extracted. After obtaining the vibroacoustic parameters for drilling, the relationship between them and the drilling SE was investigated. There is evidence that the progression of SE contributes to the magnitude of rock drilling vibroacoustic features, which could be employed to indicate energy conditions during drilling. Results obtained in this study have the potential to be used as the basis for an industrial monitoring system that can detect excessive energy consumption and advise the user of the end of the bit's useful life. This method can be an intelligent technique for measuring the behavior of real-time drilling operations based on the SE simply by installing vibroacoustic sensors on the drilling machines.

Investigating the impact of drill material on hole quality in jute/palm fiber reinforced hybrid composite drilling with uncertainty analysis

This study presents a method for modelling, predicting, and evaluating the impact of drill materials on the drilling process of hybrid palm/jute polyester composites, with the aim of enhancing hole quality regarding delamination, circularity, and cylindricity. Three drill materials, including High-Speed Steel (HSS), 5 % Cobalt-coated High-Speed Steel (HSS-Co5), and Solid Carbide drills were tested, and their impacts on drilling performance were assessed. Through thorough experimentation and statistical analysis, significant differences in results were observed between HSS drills and both HSS-Co5 and Solid Carbide drills. However, the variation in results between HSS-Co5 and Solid Carbide drill results was minimal. Additionally, the findings highlight notable disparities among drill types concerning uncertainty. The results also indicate that feed rate, drill material, and their interaction play crucial roles in determining drilling efficiency. Specifically, HSS drills consistently outperformed HSS-Co5 and Solid carbide drills, demonstrating superior performance in minimizing delamination, improving circularity, and enhancing cylindricity along with lower uncertainty.

Achieving the hydrophobic alteration by functionalized nano-silica for improving shale hydration inhibition

Shale hydration is the primary cause of wellbore instability during drilling processes. In this study, two non-fluorinated silane-coupling agents, octyltriethoxysilane (OTES) and (3-Aminopropyl) triethoxysilane (APTES), were grafted onto the nano-silica surface to develop a hydrophobic material (SHM). Various performance characterizations, including infrared spectroscopy, thermogravimetric analysis, surface tension, wetting alteration, capillary self-suction height, bentonite expansion, and shale dispersion, were employed to investigate the shale inhibition properties of SHM comprehensively. Experimental results revealed that SHM could significantly improve shale hydration inhibition. For instance, in a 2 % SHM liquids, the shale hot rolling recovery rate increased from 25.39 % to 83.78 %, and the bentonite expansion height decreased from 7.65 mm to 2.80 mm. The inhibition performance was notably superior to potassium chloride (KCl) and polyether amine (PEA). Inhibition mechanisms analysis unveiled that the outstanding inhibitory effect of SHM was achieved through electrostatic adsorption, wettability alteration, and surface tension reduction. Firstly, SHM contained numerous amine groups that could demonstrate strong adsorption on the clay surface through electrostatic and hydrogen bonding interactions. Secondly, with long hydrophobic alkyl chains, it formed a highly hydrophobic film enveloping the shale surface, effectively preventing water from invading. Thirdly, it reduced liquid surface tension, further minimizing the water infiltration. As a result, the use of SHM significantly enhanced shale hydration inhibition during the shale drilling process.

Uniaxial compressive strength prediction based on measurement while drilling data: A laboratory study

The uniaxial compressive strength is one of the most important basic parameters of rock, which is essential for surrounding rock stability analysis and support scheme design of underground engineering. At present, it is time consuming and costly to take a large amount of core samples for laboratory testing, and the mechanical properties of the cores may be affected by mining disturbance, which can easily lead to inaccurate result. The measurement while drilling (MWD) technology provides a new approach to solve the above challenge. The key to implementing this technology is to establish a correlation model between drilling parameters and rock mechanics parameters. Based on the characteristics of polycrystalline diamond compact (PDC) bits in drilling and rock breakage, this paper analyzes the mechanical state of the bit in breaking rock. A theoretical correlation model between the torque, feed force of the bit and the uniaxial compressive strength of the rock has been developed. To verify the accuracy of the theoretical model, the uniaxial compressive strength of five different types of rocks (red sandstone, green sandstone, limestone, marble and shale) was obtained through laboratory mechanical tests. The torque Mb, feed force Fb and other parameters in the drilling process of these five rocks were tested through the newly developed MWD test system. The correlation between the drilling parameters and the uniaxial compressive strength of rock was established. The results showed that the feed force Fb and torque Mb measured at five different types of rocks indicate a linear increasing trend with an increase in depth of cut h. Meanwhile, a strong linear relationship between the feed force Fb and torque Mb is evident. This paper proposes an MWD-based method to rapidly conduct the in-situ measurement of the uniaxial compressive strength of various rocks.

Drilling performance of Al-Ni eutectic alloy with scandium addition

Al-Ni eutectic alloys are an alternative alloy for high-temperature applications because of their excellent thermal stability of the Al3Ni eutectic fibers. Since the matrix of eutectic Al-Ni is weak, adding Sc to the alloy (Al-6Ni-0.4Sc) is able to increase its strength and hardness. This study is to investigate the machinability of Al-6Ni-0.4Sc alloy compared to Al-6Ni alloy through a drilling process. The results revealed that the Al-6Ni-0.4Sc alloy required less power, torque, and thrust force in the drilling process than Al-6Ni, despite having higher strength and hardness. The average specific energy for the drilling of Al-6Ni-0.4Sc alloy was 1.011 W s/mm3. This was 12.77% less than the value for Al-6Ni alloy. The chip velocity in the drilling of the alloy with Sc addition was twice that of the alloy without Sc, implying low heat accumulation in the cutting tool, less tendency for built-up edge formation, and a low wear rate on the drill’s rake face when drilling Al-6Ni-0.4Sc alloy.

Lithology identification of coal-bearing strata based on data-driven dual-channel relevance networks in coal mine roadway drilling process

The accurate prediction of coal seam thickness and the identification of the lithology of coal-bearing strata represent a crucial aspect of the intelligent perception of the stratigraphic environment. These technologies represent a fundamental aspect of intelligent mining operations with respect to coal. Accordingly, this paper concentrates on the investigation of lithology identification in coal-bearing strata through the utilization of data-driven dual-channel relevance networks in the context of coal mine roadway drilling operations. In consideration of the impact of coal seam thickness fluctuations on lithology identification, the region in question is initially delineated into two distinct categories: those comprising relatively stable coal seams and those comprising unstable coal seams. This is achieved through the application of coal seam thickness prediction and stability evaluation techniques. Subsequently, in consideration of the varying challenges posed by the region's coal seams, which can be either relatively stable or unstable, distinct lithology identification schemes are employed in different regions. In regions where the coal seam is relatively stable, there is a significant demand for classification of soft and hard coal seams. Additionally, the non-coal seam samples belong to a limited number of classes, necessitating the use of the SMOTE-GBDT algorithm to classify the coal-bearing strata into soft coal seam, hard coal seam, and non-coal seam. In the case of an unstable coal seam, the ability to distinguish between different seams is of paramount importance for lithology identification purposes. To this end, a double-layer binary classification RVM approach is employed to categorize coal-bearing strata into weak interlayer, coal seam and mudstone layer. The proposed methodology entails the utilization of diverse techniques in accordance with the specific characteristics of varying coal seam stability regions, with the objective of meticulously delineating the targets of lithology identification. This approach facilitates the generation of a comprehensive understanding of the coal-bearing strata environment, which can subsequently inform the implementation of intelligent adaptive control strategies.

Experimental Analysis of Robotic Cortical Bone Specimen Drilling Performance: Effect of Cryogen.

In orthopedic surgery, precise bone screw insertion is crucial for stabilizing fractures, necessitating a preliminary cortical bone drilling procedure. However, this process can induce temperatures exceeding 70 °C due to the low thermal conductivity of cortical bone, potentially leading to thermal osteonecrosis. Furthermore, significant cutting forces and torque pose risks of tool breakage and bone damage, underlining the need for high precision and optimal processing parameters. Traditionally, drilling relies on the surgeon's experience and often results in imprecise outcomes due to inconsistent feed rates. Therefore, this study proposes the use of a 6-axis robot for controlled drilling, offering precise control over angular velocities and consistent feed rates. Additionally, explore the use of cryogenic liquid nitrogen (LN2) as a novel cooling method compared to conventional saline solutions, examining its efficacy under various cutting conditions. The results demonstrate that LN2 cooling conditions lead to a reduction in thrust and torque under specific processing conditions, and facilitate smoother chip evacuation. Additionally, LN2 significantly lowers the peak temperature around the drilling site, thus minimizing the risk of thermal osteonecrosis. Consequently, the use of a 6-axis robot provides consistent feed rates, and LN2 cooling achieves optimal processing conditions, enabling a more controlled and effective drilling process.

Research on adaptive feature optimization and drilling rate prediction based on real-time data

In the drilling process, the rate of penetration (ROP) is an essential indicator of drilling efficiency. Accurate prediction of the rate of penetration (ROP) is crucial for improving drilling efficiency and minimizing costs. Conventional ROP predictions are typically made post-drilling, often resulting in low accuracy and limited applicability. To predict ROP more efficiently and accurately, an adaptive feature-optimized ROP prediction method based on real-time data was proposed. Initially, a fusion feature selection algorithm based on historical drilling data was designed and optimized using the Particle Swarm Optimization algorithm (PSO). On this basis, adaptive feature optimization was performed on real-time drilling datasets, and four different machine learning ROP prediction models were established using the selected feature parameters. The result shows that compared with the non-adaptive methods, the accuracy of the ROP prediction model using adaptive feature optimization is improved. The improvements are 27%, 44%, 47% and 47%, respectively, it demonstrates the significant advantages of using the designed adaptive feature optimization.

Preparation and Performance Evaluation of a Supramolecular Polymer Gel-Based Temporary Plugging Agent for Heavy Oil Reservoir.

When encountering heavy oil reservoirs during drilling, due to the change in pressure difference inside the well, heavy oil will invade the drilling fluid, and drilling fluid will spill into the reservoir along the formation fractures, affecting the drilling process. A supramolecular polymer gel-based temporary plugging agent was prepared using acrylamide (AM), butyl acrylate (BA), and styrene (ST) as reacting monomers, N, N-methylenebisacrylamide (MBA) as a crosslinking agent, ammonium persulfate (APS) as an initiator, and poly(vinyl alcohol) (PVA) as a non-covalent component. A supermolecular polymer gel with a temperature tolerance of 120 °C and acid solubility of 90% was developed. The experimental results demonstrated that a mechanically robust, thermally stable supramolecular polymer gel was successfully synthesized through the copolymerization of AM, BA, and ST, as well as the in situ formation hydrogen bonding between poly (AM-co-BA-co-ST) and PVA, leading to a three-dimensional entangled structure. The gel-forming solution possessed excellent gelling performance even in the presence of a high content of salt and heavy oil, demonstrating superior resistance to salt and heavy oil under harsh reservoir conditions. High-temperature and high-pressure plugging displacement experiments proved that the supramolecular polymer gel exhibited high pressure-bearing capacity, and the blocking strength reached 5.96 MPa in a wedge-shaped fracture with a length of 30 cm. Furthermore, the dissolution rate of the supramolecular polymer gel was as high as 96.2% at 120 °C for 48 h under a 15% HCl solution condition.

Use of a new aiming compression device and technique for the repair of navicular bone fractures in horses: A cadaveric study.

To assess the use of a newly developed aiming compression device (ACD) for screw insertion in non-fractured navicular bones (NB) in cadavers. Cadaveric study. A total of 10 cadaveric front limbs of adult horses. Placement of a 3.5 mm cortical screw in non-fractured NB under radiographic guidance was performed in 10 cadaver limbs in a standing position. An ACD was used to stabilize the NB and to guide the drilling process. Preparation and surgical time as well as the number of radiographic images were noted. A postoperative scoring system was used to assess screw placement by cone beam computed tomography (CBCT) and gross examination by two evaluators. The total procedure time was 25-62 min (median 33.5). During the procedure, 11-21 radiographs (median 18.5) were taken. The postoperative gross examination revealed an excellent screw placement in nine NB and poor in one. This could not be reliably assessed with post-procedure CBCT. The described technique achieves an excellent screw placement in 9/10 bones without disrupting the articular or flexural surface of the NB and with no protrusion of the screw head or tip, in a median procedure time of under 35 min. Adequate screw placement is paramount for NB fracture repair. The described approach under radiographic guidance allows adequate screw placement using the ACD to stabilize the NB by lateral to medial compression. This technique facilitates adequate screw placement within the NB without the use of advanced imaging techniques.