Analysis of performance and optimization of Iron Roughneck Tong Dies parameters

In automated drilling operations within the oilfield industry, the Iron Roughneck represents the most advanced torque screwing equipment currently available. It is primarily used for the make-up and break-out of drill pipes, casings, and other drilling tools, making it an indispensable component of modern drilling automation. Among its key components, the Tong Dies play a crucial role, as their quality directly affects the operational efficiency of the Iron Roughneck and the service life of tubular components. However, research on Tong Dies remains limited, with most existing studies employing orthogonal optimization methods. While these studies address localized optimization issues, they have yet to achieve a globally optimal design. This study systematically analyzes the key factors influencing the performance of Iron Roughneck Tong Dies based on their actual working conditions. The analysis includes the biting depth of the Tong Dies on the drill string and the equivalent friction coefficient between the Tong Dies and the drill pipe. Building on these insights, a global parameter optimization is conducted for critical design parameters, including the tooth apex angle, tooth height, and tooth spacing. The goal is to identify an optimal parameter combination that maximizes the equivalent friction coefficient while maintaining a minimal biting depth, thereby improving performance. Furthermore, by conducting a strength analysis of the Tong Dies and comparative experiments before and after optimization, this study verifies the significant performance improvements achieved through optimization. The findings provide a theoretical foundation and an optimization methodology for the design and application of Iron Roughneck Tong Dies.