Document Type : Original Research Paper
Authors
Department of Mining Engineering, Karadeniz Technical University, Trabzon, Turkey
Abstract
Modelling wear of drill bits can increase the efficiency in the drilling operations. Related to the subject, it is aimed to investigate the wear mechanism of drill bits. Wear in drill bits is influenced by many factors related to the drilling and rock properties. The type and intensity of wear are dependent on several complicated factors that are required to be considered in anticipating the rate of wear in the field and laboratory conditions. The laboratory tests have been performed in order to specify the relationships between the bit wear rate and the physico-mechanical properties, drillability, abrasive properties, and brittleness of rocks. Statistical analysis has been used to obtain equations for estimating the bit wear rate based on the rock properties. In this work, an ensemble technique is used to estimate the confidence interval and the prediction intervals for the regression models. This paper summaries the rock properties and bit wear mechanism, and argues the options to determine the bit wear rate. The test models indicate that the rock properties can give an idea of bit wear. They also show a good correlation between the bit wear rates. Also some models are developed to represent the wear quantification, and an approach is suggested in order to estimate the bit wear rate. The results obtained from studying the developed models provide a good agreement with the performance evaluation of an efficient drilling, which provide an indirect evaluation of drill bit wear rate during a drilling process, which can help to reduce the specific energy consumption and lower costs for the exchange of drill bits.
Keywords
[1]. Krupa V., Krulakova M., Lazarova E., Labas M., Feriancikova K., and Ivanicova L., 2018. Measurement, Modelling and Prediction of Penetration Depth in Rotary Drilling of Rocks. Measurement, DOI: https://doi.org/10.1016/j.measurement.2017.12.007, Vol. 117, Pages 165-175.
[2]. Plinninger R.J., Spaun G., and Thuro K., 2002. Prediction and Classification of tool wear in Drill and blast tunneling . In J.L. Van.Roy & C.A. Jermy (editors), Proceedings 9th Int. IAEG Congress, Durban, South Africa, 2226-2236.
[3]. Capik M., and Yilmaz A.O., 2017. Correlation between Cerchar abrasivity index, rock properties, and drill bit lifetime. Arab J Geosci 10: 15.
[4]. Bilgin N., Çopur H., and Balci C., 2014. Mechanical Excavation in Mining and Civil Industries, CRC Press.Taylor & Francis Group, Boca Raton.
[5]. Fay H., 1993. Practical Evaluation of Rock-bit Wear during Drilling", SPE Drilling Eng., 8, 99-104.
[6]. Willis J.B. and Johnson S.M., 1990. Risk and Economics Evaluation in Drilling Operations", SPE 19931, SPE-IADC Drilling Conf., Houston, Feb. 27- March 2. (1990). 65.
[7]. Singh S.P., and Alam T. A., 2013. Review on the Excavator Tool Bits Wear. Proceedings of the 1st International and 16th National Conference on Machines and Mechanisms (iNaCoMM2013), IIT Roorkee, India, December, 18-20,(2013) 823-829.
[8]. Yao Q., 2012. An Investigation of Rock Cutting: Towards A Novel Design of Cutting Bits. Doctoral dissertation. The University of New South Wales.
[9]. Roepke W.W., and Hanson B.D., 1983. Effect of Asymmetric Wear of Point Attack Bits on Coal Cutting Parameters and Primary Dust Generation", USBM, RI 8761, 16.
[10]. Thuro K., 1997. Drillability Prediction: Geological Influences in Hard Rock Drill and Blast Tunneling, Geol. Rundsch., Vol. 86, 426–438.
[11]. Ersoy A., and Waller M.D., 1997. Drilling Detritus and the Operating Parameters of Thermally Stable PDC Core Bits, Int. J. Rock Mech. Min. Sci., 1997, Vol. 34, No. 7, 1109–1123.
[12]. Howarth D.F and Rowlands J.C., 1987. Quantitative assessment of rock texture and correlation with drillability and strength properties. Rock Mech Rock Eng 20, 57—85
[13]. Warren T. M., 1984. Factors Affecting Torque for a Roller Cone Bit." SPE Journal of Petroleum Technology 36V(9), 1500-1508.
[14]. Burgess T.M., 1985. Measuring the Wear of Milled Tooth Bits Using MWD Torque and Weight-on-Bit. Paper SPE/IADC 13475 presented at the SPE/IADC Drilling Conference. New Orleans, Louisiana, 6-8 March.
[15]. Falconer I.G. and Normore. D., 1987. Well Site Applications of an MWD Bit Efficiency Model, Paper SPE 16644, Society of Petroleum Engineers.
[16]. Kuru E. and Wojtanowicz A., 1992. Theoretical Method for Detecting in situ PDC Bit Dull and Lithology Change. Journal of Canadian Petroleum Technology. 31(7), 35-40.
[17]. Rabinowicz E., 1997. Abrasive Wear Resistance as a Material Test", Lubrication Engineering. 33(7), 378-381.
[18]. Ning Z. and Ghadiri M., 2006. Distinct element analysis of attrition of granular solids under shear deformation." Chemical Engineering Science–61(18), 5991-6001.
[19]. Hutchings I.M., 1992. Tribology: Friction and Wear of Engineering Materials. London: Edward Arnold.
[20]. Rabinowicz E., 1996. Friction and wear of materials. Second edition. Toronto, ON: John Wiley & Sons.
[21]. Abbas R.K., 2015. Analysis of the wear of oil wells drill bits. Doctoral dissertation. The University of Leeds.
[22]. Mori N., Moriguchi H., Ikegaya A., Shioya Y., and Ohbi K., 2003. Development of Highly Durable Materials for Drilling Hard and Abrasive Rocks. Paper SPE 80457 presented at the SPE Asia Pacific Oil and Gas Conference and Exhibition. Jakarta, Indonesia, 15-17 April 2003. DOI: 10.2118/80457-MS.
[23]. Dupriest F.E., and Koederitz W. L., 2005. Maximizing Drill Rates with Real-Time Surveillance of Mechanical Specific Energy". Paper SPE/IADC 92194 presented at the SPE/IADC Drilling Conference. Amsterdam, the Netherlands, 23-25 February 2005.
[24]. Xiao Y., Hurich C.A., and Butt S., 2018. Assessment of rock-bit interaction and drilling performance using elastic waves propagated by the drilling system. International Journal of Rock Mechanics and Mining Sciences 105, 11–21.
[25]. Ugurlu O.F., and Kumral M., 2019. Optimization of drill bit replacement time in open-cast coal mines, Int J Coal Sci Technol, 6(3):399–407.
[26]. Cunha J.C., 2002. Effective prevention and mitigation of drilling problems, World Oil & Gas Technologies, 2, 28–34 (September, 2002).
[27]. Abbas R.K., 2018. A review on the wear of oil drill bits (conventional and the state of the art approaches for wear reduction and quantification). Engineering Failure Analysis Vol. 90, August, 554-584.
[28]. Alemdag S., Zeybek H.İ., and Kulekci G., 2019. Stability evaluation of the Gümüşhane-Akçakale cave by numerical analysis method, J. Mt. Sci. 16(9): pp, 2150-2158.
[29]. Saai A., Bjørge R., Dahl F., Antonov M., Kane A., Diop J.B., and Ojala N., 2020. Adaptation of Laboratory tests for the assessment of wear resistance of drill-bit inserts for rotary-percussive drilling of hard rocks, Wear, 456–457: 203366.
[30]. Adebayo B., 2019. Evaluation of the performance of Atlas Copco SDR4 Rotary drill in Sagamu limestone formation, Nigeria, Journal of Engineering and Engineering Technology, FUTAJEET 13:12-19.
[31]. Piri M., Hashemolhosseini H., Mikaeil M., Ataei M., and Baghbanan A.R., 2020. Investigation of wear resistance of drill bits with WC, Diamond-DLC, and TiAlSi coatings with respect to mechanical properties of rock, International Journal of Refractory Metals and Hard Materials, https://doi.org/10.1016/j.ijrmhm.2019.105113, Vol. 87,105113.
[32]. Saeidi O., Rostami J., Ataei M., and Torabi S.R., 2014. Use of digital image processing techniques for evaluating wear of cemented carbide bits in rotary drilling, Automation in Construction, Vol. 44, August 2014, PP. 140-151.
[33]. Rostami J., Ghasemi A., Gharahbagh E.A., Dogruoz C., and Dahl F., 2014. Study of dominant factors affecting Cerchar abrasivity index, Rock Mech. Rock Eng. https://doi.org/10.1007/s00603-013-0487-3.
[34]. Atlas Copco., 2013. Top hammer equipment, Secoroc Rock Drilling Tools, Product catalogue.
[35]. ASTM., 1995. Standard practice for preparing rock core specimens and determining dimension and shape tolerances. American Society for Testing and Materials, (1995) D4543, 1995.
[36]. Ulusay R, and Hudson J.A., (eds.) 2007. The complete ISRM suggested methods for rock characterization, testing and monitoring: 1974-2006. “Compilation Arranged by the ISRM Turkish National Group, Ankara, Turkey, 628
[37]. ASTM., 2010. Standard Test Method for Compressive Strength and Elastic Moduli of Intact Rock Core Specimens under Varying States of Stress and Temperatures, American Standarts for Testing and Materials, D7012-10, United States
[38]. Hannachi S., and Guetteche M.N., 2014. Review of the Rebound Hammer Method Estimating Concrete Compressive Strength on Site, Proceedings of International Conference on Architecture And Civil Engineering (ICAACE'14) Dubai, December 25-26, 2014. pp, 118-127.
[39]. ISRM., 2007. The Complete ISRM Suggested Methods for Rock Characterization, Testing and Monitoring: 1974- 2006.
[40]. Alber M., Yarali O., Dahl F., Bruland A., Kasling H., Michalakopoulos T.N, Cardu M., Hagan P.C., Aydin H., and Ozarslan A., 2014. ISRM suggested method for determining the abrasivity of rock by the Cerchar abrasivity test. Rock Mech Rock Eng. 47, 261–266.
[41]. Dahl F., Grov E., and Breivik T., 2007. Development of a new direct test method for estimating cutter life, based on the Sievers’ J miniature drill test. Tunn Undergr Space Technol 22, 106–116.
[42]. Hucka V., and Das B., 1974. Brittleness determination of rocks by different methods. Int. J. Rock Mech. Min. Sci. Geomech. Abstr. 11, 389–392.
[43]. Altindag R., 2002. The evaluation of rock brittleness concept on rotary blasthole drills. J. S. Afr. Inst. Min. Metall. 102, 61–66.
[44]. Carney J.G., Cunningham, P., and Bhagwan U., 1999. Confidence and prediction intervals for neural network ensembles. IJCNN’99. International Joint Conference on Neural Networks. Proceedings (Cat. No. 99CH36339). doi:10.1109/ijcnn. 1215-1218.
[45]. Shrestha D.L., and Solomatine D.P., 2006. Machine learning approaches for estimation of prediction interval for the model output. Neural Networks 19:2, 225–235.
[46]. Adebayo B., and Akande J.M., 2015. Analysis of Button Bit Wear and Performance of Down-The-Hole Hammer Drill, Ghana Mining Journal, Vol. 15, No. 2, 36-41.
[47]. Piri M., Mikaeil M., Hashemolhosseini H., Baghbanan A.R., and Ataei M., 2021. Study of the effect of drill bits hardness, drilling machine operating parameters and rock mechanical parameters on the noise level in the hard rock drilling process, Mesurment, DOI: 10.1016/j.measurement.2020.108447, Vol. 167, 108447.
[48]. Majeed Y., Abu Bakar M.Z., and Butt I.A., 2019. Abrasivity evaluation for wear prediction of button drill bits using geotechnical rock properties. Bulletin of Engineering Geology and the Environment, https://doi.org/10.1007/s10064-019-01587-y.
[49]. Fowell R.J., Gillani T., and Altınoluk S., 1992. Wear Characterization of Rock, EUROCK, Chester, England, 13-18.
[50]. Gehring K.H., 1997. Classification of drillability, cuttability, boreability and abrasivity in tunnelling. Felsbau 15, 183–191.
[51]. Ocak İ., Eyigün Y., Çınar M., and Nahya T., 2007. Kadıköy-Kartal Metro Tünellerinde Kullanılan Roadheader’ın Kazı Performansı ve Keski Tüketiminin Araştırılması, Ulaşımda Yeraltı Kazıları 2. Sempozyumu, (In Turkey) İstanbul, 199-206.
[52]. Madan M.M., 2008. Underground Excavation with Road header-Case Studies. World Tunnel Congress, İndia, 1073-1084.
[53]. Ramanzan C., 2019. Effects of the physico-mechanical properties of low-strength pyroclastic rocks on cutter wear of roadheaders, Vol. 428–429, 205–216.
[54]. Plinninger R.J., 2008. Abrasiveness Assessment for Hard Rock Drilling, Geomechanis & Tunnelling 1, 39-46.
[55]. Yasar S., Yılmaz A.O., and Capik M., 2014. Investigation on relationships between brittleness properties and cuttability parameters of rocks, ROCKMEC’2014-XIthRegional Rock Mechanics Symposium, (in Turkish) Afyon, 1–8.
[56]. AL-Ameen S.I., and Waller M.D., 1994.The influence of rock strength and abrasive mineral content on the Cerchar Abrasive Index, Engineering Geology 36, 293-301.
[57]. Meng F., Zhou H., Zhang C., Xu R., and Lu J., 2014. Evaluation Methodology of Brittleness of Rock Based on Post-Peak Stress–Strain Curves, Rock Mech Rock Eng, DOI 10.1007/s00603-014-0694-6.
[58]. Kahraman S., 2002. Correlation of TBM and drilling machine performances with rock brittleness, Engineering Geology 65, pp. 269 – 283.
[59]. Göktan R.M., 1991. Brittleness and micro-scale rock cutting efficiency. Mining Science and Technology, 13:3, pp. 237 – 241.
[60]. Altındag R., 2010. Assessment of some brittleness indexes in rock-drilling efficiency, Rock Mech Rock Eng, 43:361–370.
[61]. Sandvik Construction., 2013. Top hammer drilling tools, Product catalogue. THC10-6013ENG.
[62]. Boart Longyear., 2015. Top hammer drilling tools. Percussive Products. Diateam. No 2017/3.
[63]. Fowell R.J., Hekimoglu O.Z., and Altinoluk S., 1987. Drag tools employed on shearer drums and roadheaders. In: Proceedings of 10th Turkish Mining Congress of Ankara, 529–550.
[64]. Dewangan S., and Chattopadhyaya S., 2016. Performance Analysis of Two Different Conical Picks Used in Linear Cutting Operation of Coal. Arab J Sci Eng, 41, 249–265.
[65]. Bellin, F., Dourfaye A., King W., and Thigpen M., 2010. The current state of PDC bit technology. World oil , October, 53-58.
)