The understanding of the rock-cutter interaction is essential for efficient rock cutting/drilling performed with polycrystalline diamond compact (PDC) cutters in petroleum engineering and gas exploration. Finite element modeling of the rock cutting process still remains a challenge due to the complex material properties of rock, rock fracture and chip formation phenomena and large force oscillations during the dominant brittle cutting mode. A finite element study was conducted to investigate the chip formation and force responses in two-dimensional orthogonal cutting of rock. The Drucker-Prager model that incorporates a simple shear strain failure criterion was exploited to simulate the interactions between the rock and the cutter. A fully instrumented rock cutting testbed was developed to enable the measurements of the three orthogonal force components and of the uni-axial acceleration in the cutting direction along rectilinear tool-paths to evaluate the simulation results. The chip formation phenomena and force response predictions derived by the FEM simulations were in good agreement with the experimental tests.

Volume Subject Area:
Processing
Topics:
Cutting, Finite element analysis, Rocks, Brittleness, Diamonds, Drilling, Engineering simulation, Failure, Finite element methods, Finite element model, Fracture (Materials), Fracture (Process), Materials properties, Modeling, Oscillations, Petroleum engineering, Shear (Mechanics), Simulation, Simulation results
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