Penetration and impact resistance of PDC cutters inclined at different attack angles

1　ＩＮＴＲＯＤＵＣＴＩＯＮＳｉｎｃｅｔｈｅｉｎｔｒｏｄｕｃｔｉｏｎｏｆｐｏｌｙｃｒｙｓｔａｌｌｉｎｅｄｉａｍｏｎｄｃｏｍｐａｃｔ (ＰＤＣ)ｂｉｔｓｉｎｔｈｅｍｉｄ 1970’ｓ ,ｔｈｅｓｅｔｏｏｌｓｈａｖｅｇａｉｎｅｄｉｎｃｒｅａｓｉｎｇｌｙｗｉｄｅａｃｃｅｐｔａｎｃｅ .Ｔｈｉｓｉｓｎｏｔｂｅｃａｕｓｅｏｆｔｈｅｔｏｏｌｉｔｓｅｌｆ ,ｂｕｔａｌｓｏｂｅｃａｕｓｅｏｆｔｈｅａｄ ｖａｎｃｅｓｔｈａｔｍａｄｅｉｎｔｈｅｍａｔｅｒｉａｌｓｕｓｅｄｔｏｆｏｒｍｔｈｅｂｉｔｓａｎｄｉｎｔｈｅｂｉｔｄｅｓｉｇｎｓ…     

Cutting capacity of PDC cutters in very hard rock

An experimental programm of investigating the cutting capacity of PDC flat cutters in very hard rock has been performed, Experiments include both the cutting of PDC fixed at different angles on the granite core or bar and linear cutting with different static thrust on the block of granite, The effects of the rough degree of rock surface, cutting angles,and static thrust on the cutting capacity of PDC in very l‘mrd rock were investigated and analyzed. The results show that the single modp of rotarv drilling llsing PDC cutterg is not annlied fnr very hard rocks.     

单轴压缩作用下不同高宽比硬岩试样的破坏模式与板裂破坏机理（英文）

为了研究板裂破坏与试件高宽比(H/W)之间的关系以及板裂破坏的发生条件、破坏特征和力学机理,对6组花岗岩试样进行单轴压缩试验。利用应变监测仪和高速摄影仪记录试样的破坏全过程,通过分析应力、应变以及声发射的监测结果确定裂纹的发生和扩展路径。结果表明,H/W的变化可以改变试样的宏观破坏模式。当H/W降低至0.5时,试样破坏模式以板裂破坏为主;板裂破坏发生时试样承载力降低,裂纹拓展方向近似平行于加载方向。此外,发生板裂破坏的试样的裂纹扩展过程和声发射信号均呈典型拉伸破坏特征,表明板裂破坏本质上是一种特殊的拉伸破坏。     

Swept volumes of toroidal cutters using generating curves

Modelling the volume swept by a tool as it moves from one programmed position to another in three, four and five-axis milling is a challenging task. In this paper, a technique for generating the volume swept by a toroidal cutter in its motion along a given tool path, is presented. This technique is based on identifying “generating curves” along the path and connecting them into a solid model of the swept volume. The swept volume simulations are verified experimentally for three test pieces. These are also compared with the simulation results from the Z-map technique. The results of the experimental verification show the method to be accurate to within 10 μm for the three test pieces. Furthermore, the computation time for the new technique is significantly less than the Z-map method. It is concluded that the proposed method has the potential of allowing fast simulation and verification of multi-axis tool paths.     

Mechanics and dynamics of general milling cutters. Part II: inserted cutters

Inserted cutters are widely used in roughing and finishing of parts. The insert geometry and distribution of inserts on the cutter body vary significantly in industry depending on the application. This paper presents a generalized mathematical model of inserted cutters for the purpose of predicting cutting forces, vibrations, dimensional surface finish and stability lobes in milling. In this paper, the edge geometry is defined in the local coordinate system of each insert, and placed and oriented on the cutter body using the cutter's global coordinate system. The cutting edge locations are defined mathematically, and used in predicting the chip thickness distribution along the cutting zone. Each insert may have a different geometry, such as rectangular, convex triangular or a mathematically definable edge. Each insert can be placed on the cutter body mathematically by providing the coordinates of the insert center with respect to the cutter body center. The inserts can be oriented by rotating them around the cutter body, thus each insert may be assigned to have different lead and axial rake angles. By solving the mechanics and dynamics of cutting at each edge point, and integrating them over the contact zone, it is shown that the milling process can be predicted for any inserted cutter. A sample of inserted cutter modeling and analysis examples are provided with experimental verifications.     

Control of exaggerated tungsten carbide grain growth at the diamond-substrate interface of polycrystalline diamond cutters (PDC)

Exaggerated tungsten carbide grain growth is common at the interface between the diamond table and the cobalt-cemented tungsten carbide (WC-Co) substrate in polycrystalline diamond cutters (PDC). The exaggerated WC grains at the interface can grow as large as 50 μm with an aspect ratio of 50:1. These large grains can also grow as clusters. The presence of large WC grains/clusters creates weakness at the diamond-substrate interface and impairs the strength of the PDC tool. In the present investigation, we tried to understand the root cause of exaggerated WC grain growth at the interface. Our findings show that WC grain growth at the interface decreases with a decrease in the carbon/tungsten (C/W) ratio. By adding 5 wt.% pure tungsten powder to the diamond, the C/W ratio decreased and we found no WC grain growth. By adding fully stoichiometric WC, which has 6.13 wt.% carbon, grain growth was reduced but still observed. Sintering on a substrate having η-phase (carbon deficient phase) also decreased the C/W ratio, and we did not observe WC grain growth.     

石油天然气钻采用PDC切削齿的最新发展

本文介绍了近年来PDC钻头的设计理念和PDC切削齿的最新技术动向,PDC切削齿的若干关键技术,以及国际上最新采用的测试技术。通过提高金刚石含量,加强D-D键结合,优化界面几何形状,减少内应力,精细控制各种原辅材料的质量,最终提高PDC切削齿的综合性能。文中介绍了PDC超声波逐行扫描探伤技术,最新的重负荷检测耐磨性能,以及耐热性和抗冲击性的检测技术。最后还对石油钻井市场现状进行了介绍。     

Failure behavior of protective organic coatings under corrosive conditions

Recent research activities on the formation of micro-defects and porosity in organic coatings were reviewed. The mechanisms of aggressive ionic conduction through organic coatings were analyzed. The micro-mechanisms for the failure behavior of coatings under corrosive environments were discussed in detail. These mechanisms included blistering (i. e. osmotic blistering, anodic blistering and cathodic blistering) in the coating, wet-adhesion loss at the substrate/coating interface, cathodic delamination of coating from the substrate. Based on these researches, it was found that the failure behavior of organic coatings is closely related to the micro-defects in coatings, regardless of the failure mode. Additionally, the general failure mode of a coating system was proposed to interpret the failure behavior of organic in corrosion environments. The topics discussed can provide some insights into the development of a methodology for designing fail-safe coating systems.     

BGA无铅焊点在跌落冲击载荷下的失效模式与机理

通过PCB组件跌落试验,探究了BGA封装的失效模式和失效机理;分析了焊球中裂纹的产生机理及扩展特点.结果表明,BGA封装失效的主要原因是焊球裂纹和PCB结构性断裂.焊球裂纹主要有两种,分别位于焊球顶部和根部,且产生机理不同.焊球顶部由于重力导致局部钎料不足而使焊球与阻焊膜之间产生间隙,进而形成裂纹;焊球根部则是由于残留助焊剂与焊球和阻焊膜之间存在间隙,在载荷作用下形成裂纹.裂纹的扩展与裂纹源的初始位置、方向及应力情况有关,焊盘与焊球的相对位置对裂纹的扩展有重要影响.     

Oxidation behavior of copper at high temperatures under two different modes of direct-current applications

Oxidation kinetics of copper in the temperature range of 973–1173 K atP _{O 2}=21.27 kPa exhibit enhancement and deceleration in the rates with changing polarity compared to normal oxidation under interrupted mode of directcurrent application. These conditions are achieved by connecting the oxidizing copper covered with an initially formed thin oxide film to the positive and negative terminal of a dc source, respectively. However, the influence of direction of the current is found to be opposite under uninterrupted mode of impressed current flow in the same temperature range. The effect of short-circuiting the metal to the outer oxide/air interface on the reaction kinetics is also reported. The rate of oxide-scale growth under normal condition, and two different modes of current applications as well as with shorting circuitry attachment conform to the parabolic growth law. The results pertaining to the two different modes of impressed current have been discussed considering both the phenomena of electrolysis of the oxide electrolyte and the polarization at the two phase boundaries. The enhancement and the reduction in rates under uninterrupted impressed current conditions are explained on the basis of increased and decreased average defect concentrations, respectively, within the oxide layer. The acceleration and deceleration in the rates under interrupted mode of current flow have been explained in the light of sustenance of a steeper and flatter electrochemical-potential gradient of defects, respectively, across the growing-oxide layer. The possible different responses of the metal/oxide and oxide/air interfaces to the impressed current brought into play by two different modes of current application, have enabled to display a better insight on the mechanistic aspects of scale growth under the influence of an externally applied current.     

矿用截齿失效形式及对策

为降低截齿损耗,提高截齿的使用寿命,介绍了矿用截齿在工作过程中普遍存在的磨损、折断等失效形式及产生原因,并分析了目前国内常用的截齿材料及其热处理工艺,在此基础上介绍了几种提高截齿综合力学性能的措施,为矿用截齿的生产提供参考。     

X射线衍射测试PDC表面残余应力的实验研究

作者采用DIMAX2500型X射线衍射仪,通过对入射光狭缝尺寸进行调整,使X射线的照射光斑尺寸缩小为1.5×5 mm,从而实现了对PDC表面沿径向的四个不同位置的应力测量.测量采用sin2ψ法,不但测出了PDC表面不同位置的残余应力,还由此得到了PDC表面应力沿径向的分布规律,而且这一测试结果与通过有限元分析计算出的应力分布趋势基本吻合.作者还对测试值与有限元分析计算值出现偏差的原因从测试方法、有限元分析参数取值及样品表面加工方式等几方面进行了分析讨论.     

磨削印刷线路板铣刀时的锯齿现象及其消除

本文针对金刚石砂轮磨削印刷线路板(PCB)铣刀过程中铣刀切削刃产生的锯齿现象进行了分析,研究了砂轮粒度、砂轮转速以及切沟速度对铣刀切削刃锯齿的影响.研究结果表明,随着砂轮粒度的减小,切削刃质量得到提高,砂轮转速和切沟速度对切削刃质量都有影响,其中砂轮粒度对切削刃质量的影响最为重要.     

提高胎体式PDC钻头保径性能的研究

为了改善胎体式复合片钻头所存在的保径结构设计方案无地层针对性、保径效果不稳定等问题,本文设计了8只以4种方式进行保径的PDC钻头,对钻头保径性能进行了现场实验,结合实验结果,对混目金刚石提高钻头保径效果的机理进行了分析.实验结果表明,采用浓度15％的20/25目粗颗粒金刚石和10％的50/60目细颗粒金刚石作保径材料的...     

PDC钻头用浸渍钎料性能研究

依据Cu,Zn,Ni,Mn,Sn,Fe,Si和稀土元素在钎料中的作用,开发出一种新型钎料JZ-2。通过对其熔化温度、润湿性能、力学性能与传统钎料对比分析,得出该钎料在以上性能方面全面超过传统的516钎料和CuNi36Mn10钎料,具体表现为:该钎料熔化温度较低,约在1 144～1 173℃;对WC的润湿长度较高,为402 mm;抗拉强度高,为704 MPa,并且塑性加工性能好;浸焊件的抗弯强度高,约为689 N/mm2;JZ-2浸焊件冲击韧性高,约为4.22 J/cm2。     

PDC钻头发展与应用概况

PDC钻头有多种失效形式,本文根据PDC钻头失效的部位对其进行了分类,分析了PDC钻头失效的原因.从提高PDC钻头材料品质、优化制造工艺与结构几个方面介绍了PDC钻头品质提高的途径,最后总结了提高PDC钻头工作效率的方法.     

金刚石复合片主要缺陷及产生的原因讨论

本文简要介绍了在金刚石复合片（PDC）的生产和检验过程中经常出现的几种主要缺陷：如分层、欠烧、表面出现针眼和黑点等,对这些缺陷产生的原因从生成机理上进行了初步的分析,并结合作者的实践经验,提出了一些解决问题的思路和方法。     

PDC钻头不良工况分析

PDC钻头已经得到了广泛应用,但在硬地层及复杂地层钻进时,钻头寿命短,钻速低。基于ANSYS软件对PDC钻头在致密砂岩中钻进时的正常工况及不良工况的瞬态接触仿真分析,比较了各种工况下PDC钻头的应力云图。发现不良工况会导致PDC钻头局部受到集中应力的作用,这些集中力大于或远大于正常钻进时钻头受到的最大应力。长时间的不良工况会导致钻头损坏,造成进尺缓慢或无进尺。     

PDC钻头真空扩散焊接工艺正交试验研究

对PDC钻头钎焊工艺存在的问题,提出用真空扩散焊接代替钎焊制造PDC钻头.采用正交试验法,通过极差分析和方差分析,研究了PDC钻头真空扩散焊接温度、焊接压力和焊接时间等工艺参数对焊接接头抗剪强度的影响,以得出其扩散焊接的最佳工艺参数.结果表明,当采用焊接温度700℃、焊接压力150 MPa和焊接时间6h的参数组合时,可获得高强度高致密性的焊接接头,其接头抗剪强度≥500MPa.     

硬岩地层PDC钻头不良工况原因分析与改善措施

传统PDC钻头在硬岩地层钻进时,不良工况多,钻头寿命及钻进效率非常低。为了找出硬岩地层PDC钻头不良工况发生的原因,以四川元坝地区须家河组致密砂岩为例,建立单个PDC复合片切削岩层的模型,分别对模型中复合片及微小岩块进行受力分析,发现单个复合片受力随切入岩石弧长、岩石的内摩擦角及黏聚力的增加而增加。视所有复合片破岩的临界钻压及扭矩为整个钻头受到岩石的作用力,钻头受力超出转盘的输出钻压及扭矩会导致不良工况的发生。最后,从提高PDC钻头结构使其能适应硬岩钻进,及使用PDC钻头伴侣来改善PDC钻头的切削条件两方面提出了PDC钻头不良工况的改善措施。