Simulation and Experimental Study of the Rock Breaking Mechanism of Personalized Polycrystalline Diamond Compact Bits

Rock breaking is a complex physical process that can be influenced by various factors, such as geometrical shape and cutting angle of rock breaking tools. Experimental study of the rock breaking mechanism of personalized bits is restricted due to long cycle and high cost. This study simulated the rock breaking mechanism of polycrystalline diamond compact (PDC) bit by combining finite element method and experiment. The simulation was performed to shorten the period and reduce the cost of studying the rock breaking mechanism of PDC bits. A rock breaking finite element model for sting cutters of personalized PDC bit was established to simulate the rock breaking process. The crack propagation pattern, dynamic stress of rock breaking, and rock breaking mechanism of sting cutters of personalized PDC bit were analyzed. The correctness of the simulation results was verified through experiments. Results demonstrate that the rock breaking load increases with the crack propagation in the fracture initiation and propagation stages, with the maximum tangential force of 1062.5 N and maximum axial force of 1850.0 N. The load changes in a small range when the crack penetrates the rock, with the tangential force of 125.0–500.0 N and axial force of 375.0–875.0 N. The rock breaking mechanism of the sting cutters of bit is consistent with maximum tensile stress theory. The rock begins to break when the tensile stress of rock is 36.9 MPa. The sting cutters of personalized PDC bit have better wear resistance than the sting cutters of conventional bit. The average wear rates of personalized PDC and conventional bits are 1.74E-4 and 2.1E-4 mm/m, respectively. This study serves as reference for shortening the study period of rock breaking mechanism, efficiently designing personalized PDC bit structure, reducing bit wear, and enhancing rock breaking efficiency.