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Technology Reviews

Issues in Polycrystalline Diamond Compact Cutter–Rock Interaction From a Metal Machining Point of View—Part I: Temperature, Stresses, and Forces

[+] Author and Article Information
Kornel Ehmann

Department of Mechanical Engineering,
Northwestern University,
Evanston, IL 60208

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received May 1, 2012; final manuscript received August 16, 2012; published online October 17, 2012. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 134(6), 064001 (Oct 17, 2012) (10 pages) doi:10.1115/1.4007468 History: Received May 01, 2012; Revised August 16, 2012

This paper provides a comprehensive review of the literature that deals with issues surrounding the polycrystalline diamond compact (PDC) cutter–rock interface during rock cutting/drilling processes. The paper is separated into two parts addressing eight significant issues: Part I deals with fundamental issues associated with temperature/stress distribution and loading force prediction, while Part II focuses on issues related to PDC cutter/bit performance, wear and other failure phenomena, rock removal mechanism and cutting theory, rock properties, and numerical modeling of cutter–rock interaction. Experimental, analytical, and numerical methods are included into the investigation of the above-mentioned eight issues. Relevant concepts from metal cutting, micromachining, and other machining processes are also introduced to provide important insights and draw parallels between these interrelated fields.

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Figures

Grahic Jump Location
Fig. 1

Structure and components of a PDC bit. (a) ReedHycalogTM 8½ in. diameter DSX148 drag PDC bit [6] and (b) components of a matrix PDC bit [5].

Grahic Jump Location
Fig. 2

Illustration of important quantities and terminology in rock cutting area

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Fig. 3

Illustration of rake angles and characteristic forces: (a) rock cutting and (b) metal cutting adapted from Ref. [21]

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Fig. 4

Configuration of the cutter–rock interface in Glowka's model adapted from Ref. [26]

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Fig. 5

Heat generation sources in orthogonal metal cutting processes adapted from Ref. [37]

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Fig. 6

Schematic of Merchant's metal cutting model and Nishimatsu's rock cutting model adapted from Ref. [8]

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Fig. 7

Forces in Fairhurst and Lacabanne's rock cutting model

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Fig. 8

Forces in the D-D model adapted from Ref. [71]

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Fig. 9

Characteristic surfaces in Clayton's model [66]

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Fig. 10

Characteristic forces in Gerbaud's model [67]

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Fig. 11

Work-tool thermcouple circuit

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