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org ISSN 0974-5904, Volume 05, No. 04 (02) August 2012, P.P. 1083-1090

Modeling of Rock Breaking Process in Percussive Drilling and Scope of Optimization of Bit Geometry using Ansys and Catia
ANIMESH RANJAN1, SHIVAM SHAHI2 and K. PATHAK3
1

Dept of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal-575025, India 2 Dept of Mining Engineering, National Institute of Technology Karnataka, Surathkal-575025, India 3 Dept of Mining Engineering, Indian Institute of Technology Kharagpur, 721302, India Email: anim_nitk@hotmail.com, shahi.nitk@gmail.com, khanindra@mining.iitkgp.ernet.in

Abstract: This paper aims at showing the breaking process of hard rock under percussive drilling. The effects of impacts have been studied using the for FE analysis software, ANSYS. CATIA V-5(3-D modeling Package) has been used for modeling the various components involved in the analysis process. Materials used in the analysis include Carbon steel and Tungsten Carbide. Structural properties such as Youngs Modulus, Poissons ratio, tensile yield strength, Density, etc of the materials have been taken into consideration. The shape of the drill-bit has also been investigated for its optimization under direct impact force for the given rock-strata. Specific tools such as the Explicit Dynamics module (ANSYS Autodyne) and Shape Optimization module have been used to facilitate and refine the simulation results. The finite element concept has been used to demonstrate and determine the maximum principal stress variation, maximum principal elastic strain and directional shape deformation produced on impact of a drill bit on hard rock. The objective of this study is to provide a clearer picture of the rock-breaking process at a micro level. Keywords: Percussive Drilling, Rock-breaking, Shape optimization Introduction: During percussion drilling reciprocating motion is imparted to the drill rod attached with a drill bit. The raising and dropping of heavy piercing tools on the rock results in chipping and the broken materials are removed by flushing with compressed air to form the hole. Percussive drilling technique can be used for most rock formations and is best suited for low to medium strength formations. During successive stroke the drill rod is rotated, which is called Indexing, and is essential to create proper shape And favorable down hole environment. The objective of drilling is to achieve a larger average volume of crater per impact blow of the drilling tool (Hartman, 1966). The indexing renders new surface at the hole bottom at each blow. This helps in achieving a larger volume of crater per impact. Han et al, 2005 discussed three rock failure criteria that work percussive drilling. These are (): a) Critical compressive strain criteria: Failure of rock due to excessive compressional strain in loading direction b) Critical shear plastic strain criteria: Breakage of rock due to shear failure c) Tensile failure: Failure of rock when rock partially retrieves its deformation achieved from maximum compression. The rock generally fails when the minimum principal stress is beyond its tensile strength. Theoretically, the rate of penetration of a drill depends on the power output and the drilling strength of the rock (Tondanand and Unger, 1975). A basic equation for penetration rate for all type of drills is given by

R=

P SA

Where, R is the penetration rate, P is the power output, A is the cross-sectional area of drilled hole, and S is the specific energy in drilling. The penetration rate of percussion drills is basically attributed to crushing and chipping of rock at the bit interface. The volume of rock removed is, therefore, the volume dislodged by the bit under each blow of the striking hammer in the drill (Tandanand and Unger, 1975). The fundamental study of the rock breakage, stress variation in rock due to the impact action of bit and amount of optimum thrust for better rate of penetration involved in percussive drilling remains as a significant challenge. This paper is an effort to a) To clearly understand the effect of impact force on the rock. b) Finite element analysis of the breaking process of rock under impact. c) Providing input to design optimum drill bit according to the required impact and the rock property.

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Modeling of Bit Assembly and Rock Interface using CATIA: A drill bit used in percussion drilling in the Mining Machinery Laboratory of Department of Mining Engineering, IIT Kharagpur was studied. The bit assembly used and rock strata have been modeled in the 3-D modeling package CATIA. The Figure 1 show the model developed for the analysis process. Salient features of the components used in the analysis are shown in Table 1.

Development of Finite Element Model: Explicit Dynamics: Explicit dynamics analyses are used to determine the dynamic responses of a structure due to impact, rapidly changing time dependent load, or stress wave propagation. This analysis is conducted for scenarios where change in momentum and inertial effects are the important aspects. It includes various solution techniques such as Lagrange, Euler, Arbitrary Lagrangian-Eulerian (ALE) and smoothed-particle hydrodynamics (SPH), a mesh-free solver. ANSYS provides with its own explicit dynamics tool, AUTODYN, which includes finite element solvers for Computational Structural Dynamics, Computational Fluid Dynamics, Fluid-Structure interaction solvers and many more. This model shall focus on the finite element model for structural analysis. Meshing: Meshing is one of the most critical aspects of engineering simulation. Appropriate meshing is required in order to have accurate results. Keeping all aspects of meshing in mind and by the help of ANYSYS meshing tool, mesh are created in the rock and bit assembly. Tetrahedron patch independent meshing is used here. Patch independent meshing is a method of obtaining a mesh in which the faces and its boundaries are respected only when there is a load, boundary condition, or other objects scooped to its topology. Since such a mesh in dependent on loads, boundary conditions, named selections, all the scoping dependencies should be defined prior to meshing. When used for Tetrahedron Method Control, it uses a spatial subdivision algorithm where the entire geometry is enclosed by a root tetrahedron followed by subdivision of root tetrahedron until the element size requirements are met. Some features of the mesh used here are listed in the Table2 and the mesh generated is shown in Figure 2. Table 2: Features of Mesh Physics Preference Relevance Relevance Center Element Size Smoothing Span Angle Center Minimum Edge Length Transition Ratio Maximum Layers Element Midside Nodes Nodes Elements Explicit 0 Medium Default High Coarse 7.9994e-006 m 0.272 5 Dropped 9941 50174

Figure 1: Model of the Drill Bit and Rock for Analysis Geometry: Table 1: Geometric Features of the Components Used Block Drill steel (carbon Steel) Diameter: 35mm Length: 85mm Volume: 8.4634e-005 m Mass: 0.66437 kg Material : Carbon Steel Cutting bit (Tungsten Carbide) Diameter: 35mm Height: (7mm) Volume: 3.9931e-007 m Mass: 5.8698e-003 kg Material used: Tungsten Carbide

Dimensions: 16 cm * 16 cm *16cm Volume: 4.181e003 m3 Mass: 10.92 kg Rock type: Limestone

International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 05, No. 04 (02), August 2012, pp. 1083-1090

Modeling of Rock Breaking Process in Percussive Drilling and Scope of Optimization of Bit Geometry using Ansys and Catia Material Properties Limestone: Carbon steel: Density (7850 kg m-3), Youngs modulus (2 E+11 Pa), Poisson ratio (0.3), tensile yield strength (2.5 E+08 Pa), compressive yield strength (2.5 E+08 Pa), tensile ultimate strength (4.6 E+08 Pa), isotropic thermal conductivity (60.5 Wm-1C-1), and specific heat (434 Jkg-1C-1). Tungsten carbide: Density (14700 kg m-3), youngs modulus (6.3 E+11Pa), Poisson ratio (0.24) and tensile strength (0.3448 GPa), ultimate tensile strength(5.27 E+11Pa)

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Density (2600 kg m^-3), Tensile ultimate strength (4.0 e+06 Pa), Youngs Modulus (5.e+010 Pa), and Poissons ratio (0.22).

Boundary Conditions: Fixed Support: In order to prevent rigid body motion of the block due to impact, a fixed support needs to be applied to its opposite faces. Figure 3 shows fixed support being applied to the face shaded in purple. In addition, the adjacent face and the face opposite to the one shown in Figure 3 have also been fixed to constrain the translation of the block along any axes.

carried out considering the following conditions. The environment temperature is set at the same temperature as recorded during the experiment at the Mining Machinery Laboratory of Department of Mining Engineering, IIT Kharagpur. The initial velocity, before impact, is assumed to be 21 m s-1. This value has been calculated in terms of the total displacement of the drill rod and its acceleration produced with the provided blow. Initial velocity- 21 m s-1 Environment temperature- 22oC Velocity Direction-fixed along the axis of the bit Fixed support the face of the block along the axis of the bit and the two faces adjacent to it are fixed. Force - Provided to the upper face of the bit. Assumption The following assumptions were made in carrying out the analysis. The magnitude of acceleration is assumed to be 500 m sec-2. This is so because we have assumed blow per minute of the bit in such a way that the overall thrust is approximately equal to 335 Newton. As the mass of the bit assembly is 0.67kg, the acceleration comes out to be 500 m sec-2. Analysis Settings: Details of all the Important Analysis Settings Have Been Listed in Table 3 Table 3: Analysis Settings Data Maximum number of cycles Initial Time Step Minimum Time Step Maximum Time Step Time Step Safety Factor Automatic Mass Scaling Minimum CFL Time Step Maximum Element Scaling Maximum Part Scaling 1570 Program Controlled Program Controlled Program Controlled 3 Yes 1.e-005 s 5000. 11000.

Figure 2: Showing Mesh Pattern in Assembly

Figure 3: Showing the Fixed Support for the Block Initial Conditions: Since the time duration for an explicit dynamics analysis is a very small value, the analysis has been

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number of cycles is set at 600 as per the time required for impact. The initial minimum and maximum time step is program controlled, as ANSYS determines these factors based on the minimum CFL time step. Auto mass scaling is switched on and its factors are suitably changed so as to increase the time increment, otherwise the analysis will become slower and consumes lot of time. It should be noted that auto mass scaling makes the analysis process less accurate. Shape Optimization of Bit Geometry: This analysis is helpful in determining the best use of material for a body. It is used to optimize the structure of material so that the body has a maximum stiffness for a given applied load. Meshing: In this analysis patch conforming tetrahedron mesh has been used. Patch conforming tetra mesh method is a Delaunay tetra mesher with an advancing-front point insertion technique used for mesh refinement. This

method provides support for 3D inflation, built in pyramid layer for conformal quad-tet transition and built in growth and smoothness control to create a smooth size variation based on the specified growth factor. The detail of the mesh has been given in Table4. Table 4: Showing the Mesh Characteristics Physics Preference Element Size Minimum Edge Length Transition Ratio Maximum Layers Nodes Elements Boundary Conditions: Various Boundary Conditions Considered in The Analysis are Shown in Table 5. Explicit Default 1.7979e-004 m 0.272 5 23303 126793

Table 5: Boundary Conditions 1. 2. Fixed support Analysis settings The rectangular face opposite to the sharp edge is fixed so as to avoid rigid body motion. This constrains the translational degree of freedom along the vertical axis. The analysis settings are such that material can possibly be removed with least impact on overall stiffness. Hence, a program controlled solver type is used for this analysis. Line pressure =

( n ) max 0.035 (1)

= 5.12575 e+009 N/m Where, 3. Line pressure

( n ) max is maximum equivalent stress (Von-Mises) acting on the bit (value

taken from Table4) and 0.035 is the diameter of the cutting bit.

In order to obtain the optimized shape, a line pressure is applied on the cutting end of the bit. Here, the average stress is used to obtain the line pressure as the Shape Optimization module can only perform static analysis on the given geometry. Assumptions Stress distribution on the bit is uniform. Designing the Suggested Shape of Bit: To determine the best use of material, shape optimization module of Ansys workbench is employed. The aim of this analysis is to design optimum bit geometry so as to reduce material costs while ensuring that there is no significant reduction in the impact force and bit deformation does not distort the overall geometry. The Figure 5 shows the optimized geometry of the bit on application of the line pressure calculated in equation (1). The part marked in red shows the mass that can be removed from the bit geometry. An effort has been made to design a similar model using CATIA shown in Figure 6.

Figure 5: Shows Indicated Optimized Bit Geometry and the Actual Design of the Optimized Bit

International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 05, No. 04 (02), August 2012, pp. 1083-1090

Modeling of Rock Breaking Process in Percussive Drilling and Scope of Optimization of Bit Geometry using Ansys and Catia Calculation: Mass of the original bit = 5.8698e-003 kg Mass of the optimized bit = 4.702e-003 kg Reduction in mass =1.1678e-003 kg Percentage reduction in mass

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Geometry and Physical Properties of Optimized Bit: The intricate details of geometry and physical properties of optimized bit are given on table 7 = Table 7: Intricate Details of Optimized bit

1.1678e 003 100% 5.8698e 003

=19.89% Criteria of Shape Optimization: Ansys Shape Optimization tool is based on mathematical models such as Natural Shape Function Approach and Hybrid Natural Approach. In this case, the target material removed is aimed at 20% of bit geometry. Moreover, since the bit geometry to be optimized is not complex ANSYS employs the Contour Natural Shape Function to determine the best use of material under loading conditions (Chen Shen Yeh). The features of this method are given in the table 6 below: Table 6: Features of Contour Natural Shape Function Controlling Nodes Passive Nodes Domain Division Element Size Design Variable Basis Continuity across whole structure Design Shape Flexibility CAD Information Boundary None None Default None Yes Infinite No

The methodology also employs use of Mesh Perturbation algorithms which assist in division of model boundaries into densely segments connected. The geometry is then rebuilt using information contained in the defined boundary nodes. The controlling nodes and passive nodes are identified and parameters are assigned to the controlling nodes using mathematical techniques such as Lagrange Interpolation. In the next step, using the perturbation on the controlling nodes and the surface parameters of the passive nodes, the perturbation on the controlling nodes are determined. The sensitivity of the design is further analyzed whose details have been omitted here for simplification. The entire Contour Natural Shape Function is employed as the Structural Optimization or Shape Optimization module of ANSYS as a macro for implementation.

Analysis and Discussion: The simulation of the entire analysis has been carried out in certain time steps. Although the best representation could only be made through a video media, an effort has been made to break out the process into several stages and a timeline has been represented through pictorial representation in Table 8. Table 9 on the other hand gives a deeper insight into the technical details of the timeline.

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Table 8: Showing the Elaborate Analysis Steps at Various Stages of the Breaking Process

Table 9: Values of Stresses at Time-Steps during the Course of Impact Time 0 3.07E-04 1.57E-03 Stress (Pa) 0 75767 2.11E+09

depict the variation of stress and deformation at the location of impact and its vicinity. The comparative values of equivalent stress and directional deformation is available in Table 12. Future Work: The effect of indexing on the stress variation will be studied. Relation between rate of penetration, blows per minute and indexing will be determined using Finite Element Method (FEM) analysis. Conclusion: The analysis of rock breaking process in percussive drilling and bit geometry optimization has been carried out above. The effect of impact forces on rock strata has been studied and the variations of equivalent stress (Von-Mises), directional deformation have been clearly shown. The variation of equivalent stress on block with time of impact was nonlinear whereas directional deformation of the block varied linearly. Optimized bit geometry was calculated using the Shape Optimization module of ANSYS. As a result, a new bit design was drafted and a similar analysis was carried out. The results show that there was a similar variation of equivalent stress and deformation of the block with time. Moreover, the optimized cutting bit was also stable, i.e. it did not undergo large deformations due to impact stresses. All relationships between equivalent stresses, directional deformation and time of impact of block and cutting bit have been clearly represented through graphs and 3-D representations.

The maximum value of equivalent stress and directional deformation in the block after the first impact was reported to be 2.1068e+009 Pascal and 3.8991e-004 m respectively. The corresponding values for the cutting bit were found out to be 1.6465e+011 Pascal and 7.9529e-003 m respectively. Equivalent stress was found out to vary non-linearly with time of impact, where its value suddenly rises after a certain interval. Directional deformation was found to have a linear relationship with time of impact. With the use of Shape Optimization module, optimized bit geometry was predicted Henceforth, the analysis was repeated with the optimized bit keeping the boundary conditions intact. The results obtained for Equivalent Stress and Directional deformation for the block were 2.9588e+009 Pascal and 1.5233e-003 m respectively. The corresponding values for the cutting bit were 2.5433e+011 Pascal and 2.8139e-002 m respectively. Results obtained from the analysis are tabulated in Table 10. As shown in the above figures, equivalent stress and deformation increases non-linearly and linearly respectively for the time of impact. The figures clearly

International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 05, No. 04 (02), August 2012, pp. 1083-1090

Modeling of Rock Breaking Process in Percussive Drilling and Scope of Optimization of Bit Geometry using Ansys and Catia Table 10: Showing the Comparative Results of the Analysis (surface view)

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Table 12: Showing the Comparative Values of Equivalent Stress and Directional Deformation Analysis Parameters Directional deformation (x-axis)(block) Maximum Equivalent Stress (block) Maximum Equivalent Stress(cutting bit) Directional deformation (cutting bit) Original Bit 3.8991e-004 m 2.1068e+009 Pa 1.6465e+011 Pa 7.9529e-003 m Optimized Bit 1.5233e-003 m 2.9588e+009 Pa 2.5433e+011 Pa 2.8139e-002 m

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References: [1] Hartman, H.L., 1966. The effectiveness of indexing in percussion and rotary drilling, Int. J. Rock Mech. Min. Sci. Vol. 3, pp. 265-278. [2] Tandanand, sathit., Unger, F., Harold., 1975. Drillability determination- a drillability index for percussion drills, U.S. Bur. Mines, R1 8073.

[3] Han, Gang, Bruno, Mike, Lao, Khang., 2005. Percussion drilling in oil industry: Review and rock failure modelling, National Technical Conference and Exhibition, Texas. [4] Chen, Shen-Yeh., Integrating ANSYS with Modern Numerical Optimization Technology Part II: A Reverse Parametric Modeling Approach for Structural Shaping Optimization, FEA Opt Technology, S-Y.Chen@FEA-optimiation.com.

International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 05, No. 04 (02), August 2012, pp. 1083-1090