Collaborative Research: Fundamental Study and Pragmatic Enhancement of Rock Cutting/Drilling for Oil Exploration through Embedded Thin Film Sensor Arrays in PCD Inserts

合作研究：通过 PCD 刀片中嵌入式薄膜传感器阵列进行石油勘探岩石切割/钻探的基础研究和实用增强

• 批准号: 1301127
• 负责人: Kornel Ehmann
• 金额: $ 12.5万
• 依托单位: Northwestern University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2013
• 资助国家: 美国
• 起止时间: 2013-04-15 至 2016-03-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1301127&HistoricalAwards=false
• 关键词: Collaborative; Research; Fundamental; Study; Pragmatic

This grant provides funding for establishing the scientific and technological foundation for the measurement of temperatures and forces in the immediate vicinity of the contact zone between the polycrystalline diamond rock cutting insert and the rock and for the formulation of models for their prediction. Sensing will be realized by embedding micro-scale thin film thermo-mechanical sensors into the inserts only a few hundred micrometers away from the contact zone through diffusion bonding two polycrystalline diamond plates, namely, the base plate with the sensors deposited through micro-fabrication techniques and the cover that is in contact with the rock. The realization of this task will necessitate the study of the mechanics of the bonding process and the inter diffusion between the polycrystalline diamond and sensors. Static and dynamic sensor calibration methods will also be developed. The analytical model development, departing from the classical shear plane assumption, will be based on curved macroscopic crack propagation paths and statistical methods to describe the properties of the rock. The numerical Finite Element model will utilize a microcrack-based continuum damage model. Comprehensive experimental verification of the performance of the embedded sensors and of the developed models is also planned.If successful, the results of this research will lead to new tools for more efficient oil- and gas-exploration and extraction capabilities. The availability of the unique embedded sensing technology will potentially result in a quantum leap in the fundamental understanding of rock cutting mechanics and in innovative monitoring/control technologies. The ability of the sensors to provide real-time measurements of process variables from the vicinity of the insert-rock interface will allow the control of optimal penetration rates in rock drilling/cutting operations. The developed methodology will also serve as a platform for the further migration/spillover of embedded micro-sensor technologies into various areas of advanced manufacturing.

该赠款为建立科学和技术基础提供了资金，以测量在多晶钻石岩石切割插件和岩石之间的接触区附近的温度和力，并为其预测的模型制定。 传感将通过将微尺度薄膜热机电传感器嵌入到插入物中，从接触区域通过扩散键结合到距离接触区仅几百微米，将两个多晶钻石板粘合，即，基板与传感器通过微型制作技术和与岩石接触的盖子沉积的传感器。实现这项任务将需要研究粘合过程的力学以及多晶钻石和传感器之间的扩散。还将开发静态和动态传感器校准方法。 脱离经典剪切平面假设的分析模型开发将基于弯曲的宏观裂纹传播路径和统计方法来描述岩石的性质。 数值有限元模型将利用基于微击的连续损伤模型。还计划对嵌入式传感器和开发模型的性能进行全面的实验验证。独特的嵌入式传感技术的可用性可能会导致对岩石切割力学和创新监测/控制技术的基本理解的量子飞跃。传感器从插入岩石界面附近提供实时测量的过程变量的能力将允许控制岩石钻井/切割操作中最佳渗透率。开发的方法还将作为将嵌入式微传感器技术进一步迁移/溢出到高级制造领域的平台。