Multi-objective optimization of Stinger PDC cutter breaking rock parameters under intrusion-cutting action using...

Area of Science:

• Geological Engineering
• Materials Science
• Mechanical Engineering

Background:

• Polycrystalline Diamond Compact (PDC) cutters are crucial for efficient hard rock excavation.
• Optimizing cutter geometry and operating parameters is essential for improving drilling performance.
• Existing models often lack comprehensive analysis of multi-parameter interactions in rock breaking.

Purpose of the Study:

• To optimize the intrusion-cutting rock breaking parameters of Stinger PDC cutters for enhanced efficiency.
• To determine the influence of geometric and working parameters on cutter performance metrics.
• To provide guidance for the design of Stinger cutter PDC drill bits.

Main Methods:

• Numerical modeling of granite rotational breaking using Stinger PDC cutters.
• Statistical analysis using the Taguchi method to identify optimal parameter settings.
• Analysis of Variance (ANOVA) to assess parameter significance.
• Gray Relational Analysis (GRA) for multi-objective optimization.

Main Results:

• Weight on bit (P) and cutter back inclination angle (β) were the most influential parameters (65.02% and 17.20% impact ratios, respectively).
• Optimal geometric parameters: cone top angle (α) = 60°, cone top radius (r) = 2 mm, cutter diameter (d) = 15 mm.
• Optimal working parameters: β = 30°, P = 800 N.
• Optimized parameters reduced intrusion ability (IA) by 55.335% and mechanical specific energy (MSE) by 15.809%.

Conclusions:

• The study successfully optimized Stinger PDC cutter parameters for hard rock breaking.
• Achieved an overall efficiency increase of 18.229% through multi-objective optimization.
• The findings offer valuable insights for designing more effective PDC drill bits.