ANALYSIS OF PDC BIT WOBBLING AND DRILLING STRING BUCKLING by RAMKAMAL BHAGAVATULA, B.Tech., M.S.M.E.

A THESIS IN PETROLEUM ENGINEERING Submitted to the Graduate Faculty of Texas Tech University in Partial Fulfillment of the Requirements for the Degree of MASTER OF SCIENCE IN PETROLEUM ENGINEERING Approved

Chairperbn of the Co Hte

Accepted

Dean of the Graduate School May, 2004

Copyright 2004, Ramkamal Bhagavatula

ACKNOWLEDGEMENTS

I would hke to express my sincere thanks and appreciation to my academic advisor Dr. Lloyd Heinze and graduate advisor Dr. Akanni Lawal for their excellent guidance and constant support during my graduate studies, without which my efforts would not have been complete and fruitful. I would also hke to express my thanks to Dr. Paulus Adisoemarta and Dr. Akanni Lawal for their time and effort in reviewing this manuscript and making valuable suggestions as my thesis committee members. I am extremely grateflil to my parents and in-laws for their support and constant encouragement throughout my academic career. I thank my wife, Saroja for being with me against all odds and providing the moral support to pursue higher studies. I would also like to thank Dr. J. F. Lea, all the facuhy members, and my friends who have helped me directly or indirectly during my graduate studies.

TABLE OF CONTENTS

ACKNOWLEDGEMENTS ABSTRACT LIST OF TABLES LIST OF FIGURES CHAPTER I. INTRODUCTION 1.1 1.2 1.3 II. PDC Bit WobbUng DrilUng String BuckUng Research Objective and Scope of Study

ii v vi vii

1 1 4 6 8 8 10 13 15 15 21 25 31 31 37 41 41 47 50 50 55

CUTTING FORCES ON A PDC BIT 2.1 2.2 2.3 Orthogonal Cutting Principle Emst-Merchant Minimum Energy Criterion PDC Bit Force Evaluation

III.

BIT WOBBLING MODEL 3.1 3.2 3.3 3.4 Strain Energies in a Stressed Body CastigUano's theorem and MaxweU's reciprocal theorem Forces acting upon Bit and Bottom Hole Assembly (BHA) Elastic Constants of Bottom Hole Assembly 3.4.1 3.4.2 3.5 Static Conditions Dynamic Conditions

Formulation of Bit Vibrations 3.5.1 3.5.2 Lateral Vibrations Angular Vibrations

IV.

BIT WOBBLING-CALCULATIONS, RESULTS AND DISCUSSION 4.1 4.2 Example Calculations Results and Discussion

ni

V. VI.

DRILL-STRING BUCKLING: GENERALIZED ANALYTICAL SOLUTION DRILL-STRING BUCKLING-ANALYSIS AND DISCUSSION 6.1 CriticalBuckUngConditionoftheFirst-Order 6. L1 6.1.2 6.2 Point of Tangency for First-Order Critical Condition Equation Coefficients for First-Order Critical Condition

66 78 78 85 85 87 91 92 96 99 102 104

Critical Buckling Conditions above First-Order 6.2.1 Equation Coefficients for Critical Conditions above FirstOrder

6.3 6.4 6.5 VII.

ShapeoftheBuckledDrillingString Bending Moment Diagrams for First and Higher Buckling Orders Force Applied by Buckled Drill-String on bore-hole wall

CONCLUSIONS AND RECOMMENDATIONS

REFERENCES APPENDDC A B BIT WOBBLING DATA MATLAB SOURCE CODE

106 116

IV

ABSTRACT

Earlier study of failure of PolycrystaUine-diamond-compact (PDC) bits was attributed to "bit-whirUng" theory which caused cutter chipping due to down-hole bit vibrations. Based on the bit-whiri theory, the PDC bit design was modified by changing the cutters orientation, introduction of low-friction pads around the bit so that the net imbalance forces from the cutters are minimized. The "bit-whirl" theory by itself was not sufficient to address the failure mechanism as it considered only the kinematics of the bit and the geometric aspect of the bit dynamics was neglected. The study in the paper focuses on another theory known as PDC "bit-wobbUng" which takes into account the bit down-hole dynamics. Based on this theory, a kinetic model of the bit and the bottom-hole assembly (BHA) is developed. The various forces acting on the model are presented and analyzed. Sensitivity analysis is carried out on the model to study the effects of stabiUzer position, phase angle, bit velocity, bit weight, driU-coUar stiffiiess etc. on the backward cutter velocity. This study identifies possible solutions for reducing the bit-wobbUng. The theory of buckUng is appUed to derive the analytical solutions to driU-string buckUng. Based on the analytical solutions, the different buckling orders are modeled and analyzed. The buckled driU-string and bending moment profiles of first and higher-order buckUng are generated through computer programs given in the Appendix. The effect of various parameters on driU-string buckUng is studied and presented.

LIST OF TABLES

4.1 6.1 A.l A.2 A.3 A.4 A.5 A.6 A.7 A.8 A.9 A.IO

Basic Input Parameters for bit wobbUng analysis Values of x^ and xs for Critical Condition above First-Order Variation of AmpUtude with Frequency ratio for different viscous damping factor (AmpUtude in inches) Variation of AmpUtude Ratio with Frequency ratio for different viscous damping factor (AmpUtude in inches) Variation of Phase Angle with Frequency Ratio (Phase Angle in degrees) Cutter Velocity at Bit Center (Er = 5x\0^psi) Cutter Velocity at Bit Center (, = IxlO^ psi) Cutter Velocity variation with Lateral Contact Area Effect of Bit Weight on Cutter Backward Velocity Effect of StabiUzer Position on Cutter Backward Velocity Effect of DriU Collar Stiffhess on Cutter Backward Velocity for given distance of StabiUzer from Bit Effect of Damping Factor on Cutter Backward Velocity

50 90 107 108 109 110 111 112 113 114 115 115

VI

LIST OF FIGURES

1.1 1.2 1.3 2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

Test-weU ROP comparison in Oswego Umestone General Bit Whirl condition Typical cutter paths on a whirUng bit Typical configuration showing shear plane Forces acting on a Chip Relation between forces in metal cutting Components of forces in cutting face of tool Relation between forces and angles in orthogonal metal cutting Normal and shear stresses at a point in a body Normal forces and strain energy stored in a body Shear forces and shear strain energy stored in a body Energy in beams subjected to a uniform bending moment Influence coefficients for beam deflections Work done on a beam in sequence (a) and (b) GeneraUzed forces and corresponding displacements in an elastic body Free-Body Diagram of a BHA in vertical hole Free-Body diagram of a bit in a vertical hole Dynamic equiUbrium of a BHA in a vertical hole Cantilever beam with an end load Path of bit center at resonance condition Path of bit center at non-resonance condition (Frequency ratio=0.88) Path of bit center at non-resonance condition (Frequency ratio=1.30) Variation of AmpUtude with Frequency Ratio Variation of AmpUtude Ratio with Frequency Ratio Variation of Phase Angle with Frequency Ratio Cutter Velocifies on a PDC bit face Velocity of cutter at bit center {Er = 5x10^psi)

1 3 4 8 9 10 10 11 15 17 18 20 22 23 24 27 27 37 38 56 56 57 57 58 58 61 62

vu

4.9 4.10 4.11 4.12 4.13 4.14 5.1 5.2 5.3 5.4 5.5 5.6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15

Velocity of cutter at bit center {Er = IxlO^psi) Effect of Lateral Contact Area on Cutter Backward Velocity Effect of Weight of Bit on Cutter Backward Velocity Effect of StabiUzer position on Cutter Backward Velocity Effect of StabiUzer position on Cutter Backward Velocity Effect of Viscous Damping Factor on Cutter Backward Velocity Extemal forces acting upon a DrilUng String Extemal Forces acting on a driUing string section Vectorial representation of forces on a drilling string section Functions of F(x), P(x), and S{x) Functions ofG{x), Q{x), and T(x) Functions of//(x), R(x), and U(x) Critical Condition of the First-Order Length of a dimensionless unit with change in drilling mud density Critical Weights on bit for First-Order Critical BuckUng Buckling Conditions for Combination DriUing Strings Influence of Drill-CoUar size on BuckUng (I.D=1.875-m) Influence of Drill-CoUar size on BuckUng (I.D=2.5-/>z) Influence of DriU-CoUar size on Buckling (LD=3.0-z>2) Shape of Buckled Curves for Different BuckUng Orders Tangency and Neutral Points Variation with different BuckUng Orders Critical Weights on Bit for Second-Order Buckling Bending Moment Coefficient Profile for First-Order BuckUng Bending Moment Coefficient Profile for Second-Order BuckUng Bending Moment Coefficient Profile: Second buckle contacts bore-hole waU Coefficient/for calculating force on bore-hole waU due to driU string buckUng Force of Buckled DriUing String (Second Buckle Contacts Bore Hole WaU)

62 63 64 64 65 65 66 68 69 76 76 77 79 80 81 83 83 84 84 93 94 96 97 98 98 100 100

vni

CHAPTER 1 INTRODUCTION

l.lPDCBitWobbUng PDC bits were introduced in the early 1970s and have then almost replaced threecone bits for use in relatively soft, non-abrasive formations. The main Umitation of PDC bits is when driUing in harder formations or even in softer formations with infrequent hard streaks. The usuaUy high polycrystaUine-diamond compact (PDC) bit wear Umits its Ufe for use in hard formations even though higher penetration rates can be achieved with them. Figure 1.1 shows the performance analysis^ of a three-cone and a PDC bit while drilling through a section of the Oswego limestone at the Catoosa test faciUty near Tulsa. The lithology at the test is described by Winters and Onyia . From the figure, it is observed that the PDC bit driUed the Umestone at a rate three to four times that of the three-cone baseline. However, after driUing 20-ft the PDC bit rate of penetration (ROP) fell to nearly the three-cone baseUne. Glowka and Stone"^ and Zijsling^ also confirm that PDC bit wear and not the initial ROP limit its appUcabiUty in harder, more abrasive rocks.
300 120 HPU 6-10 KIPS WO TKRte-CONC IASUNE 200-

cr:
X

o
ir
100-

: *J\

260

270

280

290

300

310

320

330

340

DEPTH (FT) Figure 1.1: Test-well ROP comparison in Oswego Umestone^

From analysis of the drag-bit wear model by Warren,^ it is shown that the performance of a sUghtly duU PDC bit can actuaUy be much worse than that of a threecone bit. This is because the bearing area increases as the wear-flats grows and this reduces the stresses induced in the rocks. It has been observed by Zijsling^ that an apparently duU PDC bit, i.e., one with significant wear flats can stiU driU almost as fast as a new bit because of diamond table lips provided above the tungsten carbide. This diamond Ups acts as the contact area and not the complete tungsten-carbide wear-flat due to which the high contact rock stresses are stiU maintained. The presence of diamond Ups is important for efficient driUing in hard formations. However, they are not critical while driUing softer formations. A sharp bit is one which has diamond Ups provided on enough cutters to cut the bottom of the hole completely. A duU bit is one that does not have enough Ups on the cutters to cover the entire hole. PDC bits with diamond Ups are able to outdriU PDC bits by two mechanisms: (1) they create higher contact stresses because only the diamond contacts the formation on a sharp PDC bit, and (2) they are able to clean the bottom of the hole mechanically and are therefore not as greatly affected by mud, hydrauUcs and rotary speed. PDC bits fail mainly due to cutter chipping. Warren and Sinor^''^ have shown that steady-state loads applied to PDC cutters under most normal driUing situations are too low to cause cutters to chip. Even fatigue from cycUc loading of the bit is not attributed to the cutter chipping. It was observed from laboratory driUing^ that failure occurs mainly due to impact loading caused by bit vibrations which were so severe that it caused PDC studs to break and numerous cutters chipped. Even though force balancing on the PDC bits was carried out, the primary cutter chipping mechanism due to bit vibrations could not be overcome initiaUy. Warren et al^ has shown that cutters that chip develop wear flats very quickly. Once a diamond table is lost because of chipping, the tungsten-carbide wear process proceeds very quickly. They also observed that a "low-friction" bit design can substantiaUy eliminate bit whiri. The lowfirictiondesign is based on placing the cutters so that the net imbalance force from the cutters is directed towards a smooth pad that slides along the well bore waU. The detrimental effects caused by impacts loads are

attributed to a phenomenon caUed "bit whiri" or bit "backward whiri." Bad bearing design was known to produce the bit whiri. With bit whiri as shown in Figure 1.2, the bit moves primarily laterally around the hole. The bit acts as a pinion in a hole that acts as a gear. The drilUng imbalance pushes one side of the bit against the borehole wall creating a new fiictional force. A clockwise torque on the bit combined with this frictional force moves the instantaneous center of rotation away from the geometric center and towards the wellbore waU. Hole

Hole Center

Bit Centr

Figure 1.2: General Bit Whirl condition'

Figure 1.3 shows the typical cutter paths on a whirUng bit. It is observed that the cutters can move backward, sideways, and farther per revolution than those on a tme rotating bit. As a result, they are subjected to high impact loads. On a whirUng bit, a cutter impacts the side of the well bore many times per revolution. The detrimental effect of bit whirl is that it cannot be stopped once started. Hence, bit whirl occurs when the dynamic forces on a bit cause the center of rotation to move as the bit rotates. A whirling bit cuts an overgauge hole, and the cutters move faster, backwards, and sideways and consequently are subjected to high impact loads. Once a bit begins to whirl, forces are generated that reinforce this tendency. Bit whirl is worse at higher rotary speeds because the centrifiigal forces are squared as rotary speeds double. Bit whirUng becomes severe at

low weight on bit (WOB). Extemal stabilization by providing stabiUzer bars and shock subs can limit the extent of bit whirl but not eUminate it. Greater driUing force imbalance, longer driU-bit tapers, more aggressive cutting structures and gauge cutters increase a bit's tendency to whirl. Higher back rake angles, flatter profiles and smooth gauges tend to reduce bit whirl. Bit whirUng is not severe while driUing soft formations. Rocks that are driUed slowly promote bit whirl because the bit has more time to create a regenerative stmcture on the bottom of the hole. Formations that cause bit baUing also reduce bit whirling tendencies by creating a less aggressive gauge.

DM f . Ift.

'-N
2

\
Whlrl di. of bU Eytt Lobttt

<

i V^
\ 'i

. .

..'

WMrl palh of conter ol bll Roundod Lob

V
4
* : *

. ^

*A

-4

-a

*a

*i

X AXISt iN. Figure 1.3: Typical cutter paths on a whirling bit The theory of bit whirl in developing anti-whirl bits had some limitations in its appUcability. The bit whirl theory was based on analysis of bit kinematics, i.e., only the geometric aspects of the bit were considered. 1.2 DriUing String Buckling Knowledge of driUing string buckUng plays an important role while designing a driUing program. Several Uterature is available that focus on determining the buckUng and lateral vibrations of a driU-pipe. One such study^^ involves calculating the critical

buckUng loads and natural frequencies of lateral vibration modes for a long vertical pipe, suspended in a fluid, simply supported at the top and vertically guided at the bottom. Another study aims at determining the critical weights and natural frequencies for different end conditions. The fatigue and failure analysis of a drill-string^^ plays an important role when driUing into deeper formations. Without weight on the bit, a drilUng string wiU be straight if the hole driUed is straight. With a sufficienfly smaU weight on bit, the string remains straight. As the weight on the bit is increased, a so-caUed critical value of the weight is reached for which the straight form of the string is no longer stable. The driUing string buckles and contacts the waU of the hole at a point caUed the point of tangency. If the weight on the bit is fiirther increased, a new critical value is reached at

which the driU-string buckles a second time. This is termed as the buckUng of the second order. With stiU higher weights on the bit, buckling of the third and higher orders occur. At the point of tangency, the driUing string rabs against the wall of the hole, and this cause caving in the formation. The rabbing effect becomes worse when the force between the buckled pipe and the wall of the hole increases. When the buckled string is rotated, some reversing stresses due to bending are created. These stresses increase with the diameter of the hole and result in the fatigue failure of the hole. As soon as a driUing string buckles in a straight hole, the bit is no longer vertical and a perfectly vertical hole cannot be driUed. A certain point of a driUing string is usuaUy designated as the "neutral point." The "neutral point" is defmed as a point in the drilUng string below which the weight of the driUing string in mud is equal to the weight on the bit. Each value of the weight on bit corresponds to a value of the distance between the bit and the neutral point. The critical value of this distance depends upon the type of pipe or driU coUars and the density of the driUing mud. The distance between the bit and the neutral point is measured in terms of dimensionless units so that the resuUs obtained are indepndent of the type of pipe, coUars, and mud.

1.3 Research Objective and Scope of Studv The kinematic relationships derived for the bit whirl theory were used to describe the lobed pattems observed in the field and laboratory. Analysis of bit kinetics (kinematics and dynamics) which also account for the dynamic forces acting on the bit would give further insight into the various parameters that affect the bit whirUng. This study presents a "Bit WobbUng" model that is based on the bit kinetic analysis. The eventual goal of this research is to develop a mathematical model that can characterize the influence of various parameters on bit wobbling and broaden its appUcabiUty to a better understanding of bit wobbUng. The results obtained from this model would help in understanding the parameters affecting bit wobbUng and eventuaUy lead to incorporating these factors in the design of PDC bits that can further reduce wobbUng. The influence of the foUowing forces on the bit is considered in the modeU a. Forces from the BHA (Bottom Hole Assembly), b. Forces from the adjacent bore-hole waU, c. Cutting Forces on the bit, d. Forces from driUing fluid and stabiUzer. The study of driUing string buckUng includes formulation of a generaUzed dimensionless solution that can be used for any driU-pipe and driU collar size. The critical values of weight on the bit and the shape of a buckled drilling for first and second buckling orders are determined. The magnitude of the forces acting at the first buckle for these buckling orders is also determined. Finally, the bending moment diagrams are generated that help in evaluating the bending moments acting along the length of the drilling string. The results from this study give an in-depth understanding of the buckling principles involved and yield solutions to the various factors affecting buckling and how to minimize or avoid buckling. The bit kinetic analysis presented in this study is limited to the analysis of PDC bits only. It cannot be used for analysis of three cone bits, rock bits and other commercial types of bits. This is because the cutting forces evaluation for PDC bits are derived from the theory of metal cutting principle. The similar principle cannot be appUed for other

types of bits as the cutting action is different for different types of bits. The cutting forces are also dependent on the geometry of the bit and the alignment pattem of the cutting faces on the bit. The effect of weight on the bit and rotary speed on the bit vibrations is not taken into account in this model as the effect of drilling parameters on the fluctuations in cutting torque and cutting forces are not clearly known. It is anticipated that using higher weight on bit and shock absorbers will be helpfial in reducing fluctuations in the cutting torque and cutting force, and therefore backward velocity. Although increasing rotary speed may reduce the backwards velocities of gauge cutters, it wiU not significantly affect the backward velocities of cutters near the bit center because of less rotational velocity contribution to the total velocity near the bit center. The drilling string buckling analysis study is limited to drill-strings having constant material properties for both the drill-pipe and the drill collar throughout the entire considered length. As the analysis is performed using numerical methods, the results obtained represent the approximate values. For analysis simplification, the length of a one-dimensional unit is considered to be approximately equal for both the drill collar and the drill-pipe. The length of a one-dimensional unit of the drill collar is taken as the dimensionless unit for the entire drilling string in the analysis. The material properties and stiffiiess of the drill-pipe and drilI-coUar couplings on the drilling string buckling tendency is assumed to be negligible in the analysis.

CHAPTER 2 CUTTING FORCES ON A PDC BIT

2.1 Orthogonal Cutting Principle The cutting forces on PDC bit cutters are determined based on the theory of metal cutting principles. Figure 2.1 shows a typical confguration where the tool is considered stationary and the work-piece is moved to the right. There is a plane in the work-piece just ahead of the cutting tool where the shearing stress is a maximum. If the metal is ductile so that it does not fracture initially, then there will be a plastic flow along this plane called the shear plane.
* ct

^c-^

-^o^
"^^
_

/Ch,p f
/
:-J Tool \

'ii^^^r;:. Workpie ce'':ry^'

'/''V:'-\--''fC.

Figure 2.1: Typical configuration showing shear plane Source: Paul H. Black*^ - Theory ofMetal Cutting, 1961. Thus, the chip is formed by plastic deformation of the grain stracture of the metal along the shear plane. The angle that the shear plane makes with the horizontal is called the shear angle, . The chip generated due to the shearing of the work-piece material glides upward along the cutting face of the tool. The angle the cutting face of the tool makes with the normal to the fmished surface is called the rake angle, a. A relief angle is provided between the bottom face of the tool and the machined surface. This is necessary to prevent rabbing between the tool and the machined surface due to fiiction. The orthogonal or two-dimensional type of cutting is used to determine the cutting forces as it is a relatively simple model rather than the more complicated oblique cutting or three dimensional cutting. The oblique cutting model is developed from the principles of the orthogonal cutting model. Orthogonal cutfing is "the case where the 8

cutting tool generates a plane surface parallel to an original plane perpendicular to the direction of relative motion of the tool and work-piece. The forces acting on the chip in orthogonal cutting are shown in Figure 2.2 (a) and are as follows: Force Fs is the resistance to shear of the metal in forming the chip. This force acts along the shear plane. Force F is normal to the shear plane and is a "backing-up" force on the chip provided by the work-piece. Force A''acting on the chip is normal to the cutting face of the tool and is provided by the tool. Force F is the fiictional resistance of the tool acting on the chip. This force acts downwards against the motion of the chip as it glides upward along the tool face. Figure 2.2 (b) shows the forces acting on the chip in which the resuUant of the forces Fs and F^ and the resultant of the forces F and A^ are represented by R and R respectively. There are only two combined forces, i.e., i? and R that are acting on the chip. There are extemal couples that act on the chip and curl it but they are neglected in this analysis. For equilibrium to exist, the two forces R and R must be equal in magnitude and opposite in direction and have the same line of action. The components of the force of the work-piece on the chip are the shear force Fs and the normal compressive force F.

Figure 2.2: Forces acting on a Chip Source: Paul H. Black^^ Theory ofMetal Cutting, 1961 Figure 2.3 shows a composite diagram in which the two force triangles of Figure 2.2(b) have been superimposed by placing the two equal forces R and R together. Since the angle between Fs and Fn is a right angle, the intersection of these forces Ues on a circle of diameteri. The horizontal force component Fc and the vertical force component

Ft can be laid as shown in Figure 2.4 and the coefficient of fiiction can be determined by evaluating forces F and N from the geometry. From Figure 2.4, the forces F and A^ are determined as follows:

Figure 2.3: Relations between forces in Figure 2.4: Components of forces in metal cutting cutting face of tool Source: Paul H. Black^^ Theory ofMetal Cutting, 1961 F = F. cos a + F sin a N = F^ cosa - F, sina The coefficient of fiiction is defined by: F K cosa + F sina |a = tanT = = N F c o s a - F j sina or
1^ =

Fj +F^ tana F^ -F^ tana

where T is the friction angle and is the angle between the resuUant force R and the normal force N.

2.2 Emst-Merchant Minimum Energy Criterion The Emst-Merchant solution is derived using the minimum-energy criterion which states that the shear plane is located where the least energy is required for shear.^^ This criterion is used to establish a relationship of the shear-plane angle, in terms of the 10

rake angle, a and the friction angle, T. The derivation of the Emst-Merchant equation is based on the following assumptions: 1. There is orthogonal cutting. 2. The shear strength of the metal along the shear plane is not affected by the compressive (normal) stress acting on that plane. 3. The energy required for separafion of chip elements is negligible and the minimum energy criterion establishes the plane on which the shearing formation occurs. In beginning a cut in metal cutting operation, as the cutting force Fc increases gradually, the shear stress on various planes ahead of the tool will increase along with Fc but the stress wiU not be the same on all planes ahead of the tool because the shearing components of the forces on the planes are not the same. On one of the planes, however, the shear stress wiU be greater than on any other, and as F^ isfixrtherincreased, the shear stress on that plane will reach the yield strength in shear of the material being cut and plastic deformation will occur along that plane, thus forming the chip. The cutting force required to cause shear deformation along that plane identifed by as shown in Figure 2.5 will then be the lowest cutting force to produce a chip.

Figure 2.5: Relation between forces and angles in orthogonal metal cutting Source: Paul H. Black^^ Theory ofMetal Cutting, 1961.

11

Shear deformation along any other plane would require a greater cutting force, but after shear deformation begins on one plane, the cutting force cannot exceed that minimum value. This process is an applicafion of the principle of minimum energy in that the cutting force F^ is responsible for the work done in metal cutting, so that, for given rake angles a and friction angles T, the shear-plane angle wiU assume such a value as to make the energy required or work done by Fc a minimum. To determine the shear plane angle (p, an equation for the cutting force Fc is developed in terms of and differentiated with respect to cp. The resulting equation is equated to zero and solved for the angle . From the geometry of Figure 2.5, we get F. = i cos(r - a) F^ = R cos((Z> + r - a ) or p^^F,cos(T-a) cos((z} + r - a ) ^ ^ ^^

If the cross-sectional area of the un-deformed chip be represented by A, then the area of the shear plane will be equal to A/sin . The force Fs on the shear plane can be replaced by the stress on the plane multiplied by the area, or sin^ Substituting the above equation in equation 1, we get Fc = S^Acos(r-a) ^ ^ sin^cos(^ + r-:ir) ^^ ^^ ...(2.2)

Differentiating equation (2.2) with respect to the shear angle, and equating to zero, we get dF , ^ - cos cos(t) -\-T -a) + sin sin(f) + r - a ) - = S,A cos(r -a)x =0 d^ sin (zcos ((p-\-T-a)

cos ^ cos((z) + r - r) - sin ( sin((z) + r - a ) = 0 Z cos((Z) + (z) + r - a ) = 0 cos(2^ + r - a ) = 0 12

2^ + r - r = or 2 , ;r a r < = T + T-:7 ^ 4 2 2 2.3 PDC Bit Force Eva uafon The forces on the PDC bit are evaluated by applying the Emst-Merchant minimum energy criterion. From equation (2.2), we get
F =

...(2.3)

SAcos(T-a) sin^cos(^-\-T-a)

S^Acos(T-a) sin (z)[cos (^ COS(T -a)- sin ^ sin(r - a)] _ iS^^cos(r-a) [2sin^cos(^cos(r -a)-2sin^ _ ^sin(r - a ) \

2S^Acos(T-a) [sin 2(z) cos(r -a)-(lcos 2(Z>) sin(r - a)] 2S^Acos(T-a) [sin 2^ cos(r - T) + cos 2^ sin(r -a)_ 25'^^cos(r-a) [sin(2^ + r - ) - sin(r - a)]

sin(r - T) J

71

But, 2<f)-\-T-a = from equation (2.3), hence above equationbecomes 25',^cos(r-<:ir) sin()-sin(r-a) 2 ^iS^^cos^r-r) 1 - sin(r - a) ^^_2S,Acos{T-a) 1 - sin(r - a) The above equation represents the force on the bit in the vertical direction. ^2.4)

13

Similarly, the force Ft from Figure 2.5 is given by: P S^Asin(T-a) sin^cos((Z + r - a ) ^2.5)

Applying the above procedure to evaluate the denominator of equation (2,5) along with the minimum energy criterion, we get the fnal form of equation (2.5) as P ^2S^Asin(T-a) 1 - sin(r - a) The above equation represents the force on the bit in the horizontal direction. ...(2.6)

14

CHAPTER 3 BIT WOBBLING MODEL

3.1 Strain Energies in a Stressed Bodv Before the mathematical model of Bit Wobble is derived, the different kinds of strain energy that can be stored in a stressed body are considered initially. The concept of strain energies are applied in generating the model that will be discussed later. The different types of strain energies are: a. Strain energy due to direct shear, b. Strain energy due to normal stress, c. Strain energy due to torsional load, d. Strain energy due to bending. y\

Figure 3.1: Normal and shear stresses at a point in a body Source: A.H.Burr, J.B.Cheatham^^, Mechanical Analysis andDesign, (2"^Edition), 1999. Consider a body subject normal stress o and shear stress T as shown in Figure 3.1.^^ Normal strain or unit elongation is designated by s and shearing strain or angle of distortion by y. The modulus of elasticity, shear modulus and Poisson's ratio are represented by E, G, and y, respectively. In an orthogonal coordinate system, the elasticity stress-strain relations are given by

15

^x =

(^x-r(<^y+crz)]

^y=-[(^y-r{<^x+(^z)]
^z=-[rz-r(cr;,+c7y)]
and

(3.1)

=1
rxy

-1
ryz

-1
^zx ~ ^ ^zjc

^ ^xy '

'^yz '

(3.2)

In Figure 3.1, the first subscript to a shear stress T indicates the direcfion of the normal to the plane on which it acts, and the second subscript indicates the direction of the stress on this plane. Asr^y =
yx xy
'^zy

yz

andr^^ = \T^J , the three equations of

equation 3.2 are suffcient. Moduli G and E are related by

G=

...(3.3)

2(l + r)'
The unit change in volume of an element with sides of initial length dx, dy and dz is called the volume expansion e, and it is seen to be the sum of the volume changes in each direction divided by the initial volume, i.e.,

(s^dx)dy dz + (Sydy)dz dx + (s^dz)dx dy e= dx dy dz

S-^ -\- S y + S^^ .

(3.4)

Substitution of equations 3.1 into equation 3.4 gives the following linear relationship between volume expansion and the sum of any orthogonal set of normal stresses. If w, v, and w denote the displacements of a particle in the body along the^, Y,

16

and Z axes, respectively, then the stresses and strains can be represented by the following equations: du ^x^ dx
^y = V

dw ^z =

dy

. (3.5)

du yxy='^ y

dv dx'

v ^y^'dz'^

dw dy'

^''~

dw du + dx ^ dz

(3.6)

y\

aydxdz

Oxdydz

Defiection

z^x

(b) Normal forces and deflections of an element along with volume changes. Strain Energy (shaded area) with deflection

Figure 3.2: Normal forces and strain energy stored in a body Source: A.H.Burr, J.B.Cheatham , Mechanical Analysis and Design, (^"'^Edition), 1999. The work done on a body is stored in it as potential energy of deformation or strain energy. The deflections s^ dx, Sy dy, and s^ dz of Figure 3.2(a) are the result of the normal forces CTJ^ dy dz, a^ dx dz, and a^ dx dy , respectively, applied to the three faces of the element. The action at the positive x face is plotted in Figure 3.2(b). The work done is the average force times its deflection, or the area of the area of the triangle {\I2}^^ dy d^ j^Sy. dx). By a shear force couple such as (T^y dy dz)(dx) in Figure 3.3(a),

17

the work done is its average value times the angular deflection y^y l^ that it causes. By the two couples on the element, the total strain energy due to direct shear on two opposite faces is given by:

[/,. =(l/2)(r,^ dy dz){dx){Y^j2)^(\l2)(T^^

dx dz){dy)(r,j2)

= (l/2)T^^ r.y dx dy dz.

The total strain is given by

(3.7)

U,t = (1 / 2)(T^y rxy + T^yz Yyz + ^zx Yzx )dx dy dz

or, Strain Energy per unit volume is given by

Ustv = (1 / ^)(^xy Yxy + V

^y^ ^ ^^^ ^^^ ^

Xyj^xdz

{x^/iydz)dx
J2>

Jydz

D O

o
to

x:
Ang

(a)

(b) Strain energy with angular distortion due to shear-force couple

Angular changes due to Shear forces and distortion of an element

Figure 3.3: Shear forces and shear strain energy stored in abody Source: A.H.Burr, J.B.Cheatham^^ Mechanical Analysis andDesign. (2"^Edition), 1999.

18

If the body is acted upon only by shear forces, then in general the strain energy due to direct shear can be defined by Strain Energy = (1/2)* Z (Shear Stress * Shear Strain) * Volume of body. Similarly by considering the area of triangle in Figure 3.2(b), the strain energy due to normal stress is given by:

Uat ={^l2)((7^s^+c7ySy^(j^

s^)dxdydz.

... (3.8)

If the body is acted upon only by normal forces, then in general the strain energy due to direct normal stress can be defined by

Strain Energy = (1/2)* 2 (Normal Stress * Normal Strain) * Volume of body. From equation 3.7, the strain energy can be represented by [7^ = V where V

2G is the volume of the body. If the cross-secfon of the body is circular as in case of a drillpipe, then the cross-secfonal area at any point at distance x from the axis of the shaft is given by: da = 2 xdx and

Volume, dV= l "^ 2"^ "^ dx.

For a hollow drill-pipe, the torsional stress varies from zero at the central axis to a maximum stress at the outside diameter. Let the magnitude of the maximum shear stress be T at the outer surface. Then the shear stress at a given section is defined by:
X

q = rx

Ri where R^ = extemal radius of the drill pipe. 2 Strain energy stored at this section = XIXITVxdx

19

^2

2C

X - - x l x l n xdx
R}

xlnl 2CRI

X dx.

The total strain energy is stored in the drill-pipe is obtained by integrating the above equation from intemal radius, Ri to extemal radius R^.
R2
_2

R,

xlnlx 2CR2
R.

dx

T nl X CRI
-^R.

'-i(4-R)
ACRI
...(3.9)

AC

^"^^"^^KiRl-Rhl='"^^''^'^ R2
4C

V DI

Figure 3.4: Energy in beams subjected to a uniform bending moment Source: A.H.Burr, ].B.Cheatham^\MechanicalAnalysis and Design., (2"*^ Edition), 1999.

20

The strain energy due to bending can be analyzed by considering a beam subjected to a uniform bending moment as shown in Figure 3.4. Let the radius of curvature of the bent beam be equal to p and the angle of the arc at the center be equal to di . The work done on the beam by a moment that increases from zero to a value Mj is the average moment multiplied by the angle of rotation di or (M//2) i. It is represented by the shaded area on the Mversus 9 diagram. If the length of the beam is equal to /, then p6i = lox 6'i = P If the moment of inertia of the beam and modulus of elasticity be represented by / and E respectively, then M E 1 = or / P P Ml
EI

M EI

dl. EI Hence, the strain energy stored due to bending for beam length, dl can be written as: M M^ dUu =d = ^^^dl. ^ 2 2EI The total strain energy due to bending can be obtained by integrating the above equation from zero to length, /. ^M^ Ut = ljjjdl
0

m a 11 then d If the angle 61 and length / bessmall, thfin lf) =

...(3.10)

3.2 CastigUano's theorem and MaxweU's reciprocal theorem An influence coefficient is defined as the displacement of a body at one location due to a unit force applied at the same or some other location. Consider the loading of a beam^"^ shown in Figure 3.5 (a), ^22 is the deflection at location 2 due to unit load at 2, and aj2 is the deflection at location 1 due to a unit load a 2. Loaded with a unit force at

21

location 1, as in Figure 3.5 (b), the deflection at 1 is an and the deflection at 2 is a^,. The value of the coefficient can be determined analytically or experimentally by applying a load, measuring the corresponding deflection at the desired location and dividing deflection by load. In Figure 3.5 (c), the same beam is loaded by forces Pi and P2 and the "mfluence" of P^ on the deflection at location 1 is the product oaijPj, etc. so that total deflection at a given point is:

Vj = aiiPi

+ 12-^2 ^nd V2 = 0C2\Pi + 22-^2

(3.11)

ra)

(b)

(0
Figure 3.5: Influence coefficients for beam deflections Source: A.H.Burr, J.B.Cheatham , Mechanical Analysis and Design, (2"^^ Edition), 1999. Two work sequences are used to prove the theorem of reciprocity. In Figure 3.6 (a), a force applied at location 1 is built up from zero to a value Pi, while doing the work Pi{aiiPi)/2. This is foUowed by a buildup in P2, which does the work P2 {0.22^2)^2 at location 2, while the constant force P/ moved through the distance anP^ and does the work PiianP^). If there is no deflection at the supports, no work is done there.

22

12^2

022^2

aiiPi

P-,

^'''1

Figure 3.6: Work done on a beam in sequence (a) and (b) Source: A.H.Burr, J.B.Cheatham^^ Mechanical Analysis andDesign. (2"^Edition), 1999. The total work done and the energy stored is given by:

U = ^anPi^ +^a22P2 +o^nPiP2-

In the sequence shown in Figure 3.6 (b), force P2 is applied first, doing work P2(0.22^2)12, followed by Pj with work Pj(a]jPj)/2, and additional work by P2 of amount ^2(0.21^})The total work or energy stored is given by:

U = ^anPi

^^cciiPi

+^21^1^2

Since the fmal energy stored must be the same irrespective of the sequence used, from the above two equations the condition then becomes that ...(3.12)

a2j-aj2

23

This proves the theorem of reciprocity and states that, the deflection of a beam at location 2 due to unit load at location 1 is equal to the deflection at location 1 due to unit load at location 2. This theorem applies to other loads and locations as well, and in general o.mn=o.nm. It appUes uot ouly to beams, but to any elastic body. Consider Figure 3.7 that shows different forces and moments acting on a body of irregular shape. With reference to Figures 3.5 and 3.6, let all the forces increase together, starting at zero and each at a uniform rate such that all forces reach their fnal value at the same time with the displacements increasing in proportion.

O Figure 3.7: Generalized forces and corresponding displacements in an elastic body Source: A.H.Burr, J.B.Cheatham'^, Mechanical Analysis andDesign, (2"*^ Edition), 1999. The total work equal U = - Pi^i ^-P^S^ which in terms of influence coefficients is +... + -Pn^n

U = -P\{anPi

+a\2P2 +- + a\nP) + -P2(a2\P\+a22P2++ annPn)-

+ CX2nPn)

+ ... + -Pn(an\P\+an2P2+-

Differentiating above equation with respect to force P^, yields

24

dU

^ 2 . ^ ^2 dP2 = T^1^12 +-(^21^1+2^22/^2 +-.. + ^ln^n) ) + - + ^^;.^2 2 ' '" 2 ^' ' --ll^l

Applying the reciprocity theorem to above equation and adding the terms, we get

a2iPi+a22P2+--^OC2nPn=S2

since the sum is by definition equal to the displacement at location 2. Generalizing this, the CastigUano's theorem is obtained which states that, the partial derivatives of the total strain energy in an elastic member or stmcture with respect to any of the extemal "forces" is the "displacement" of the point of appUcation of that force in the direction of the force. In equation form the theorem is written as:

. dU ^^ dU Sn =^and^ = . " dP^ dM^

...(3.13) ^ ^

This theorem can be used mainly in the analysis of curved beams and rings and also for analysis of stmctures.

3.3 Forces Acting upon Bit and Bottom Hole Assembly (BHA) A free-body diagram of a BHA section^*^ between the bottom stabilizer and drill bit in a vertical hole is shown in Figure 3.8. The centroidal axis of the BHA section is assumed to be vertical at the point where the bottom stabilizer is placed. Below this point, the BHA deflects slightly from the vertical axis die to the forces from drill bit and the inertial force due to rotation of the drill collars. The reference axes x djxy are within the maximum deflection plane which is rotating at a circularfrequencycoy. Forces acting upon the BHA section include forces from the stabilizer, drilling fluid, gravity and drill bit. General forces acting upon the BHA section from the stabilizer are axial force in the x-direction Fsx, shear force from stabilizer in j -direction Fsy,

25

bending moment from drill string above stabilizer M and torque from drill string above stabilizer T^. The forces from the drilling fluid include the viscous damping force / > in the lateral direction and viscous damping torque from drilling fluid on drill coUars 7>. These two forces are generally small when compared with the other forces and can be neglected in the analysis. Forces from the bit include axial force Fb^ acting along the xaxis of the BHA section, shear force from bit in the j^-direction Fby, torque from drilling bit Tb, and bending moment from bit M^. The weight Wc of the drill collar section acts vertically downwards at the centroid of the section. The various forces acting upon the Bit are shown Figure 3.9. Forces acting upon the bit from the drill collar are the bending moment from BHA section Mc, axial force in the x-direction Fcx-, torque from drill collar Tc, and shear force from driU coUar in the;^direction Fcy. Forces acting upon the bottom of the bit are axial force from formation in the x-direction F^-, cutting torque from formation 7}, and shear force in the jv-direction Ffy. The force Ffy is zero if the bit teeth are arranged symmetrically. Forces from the drilling fluid are the buoyant force Fp, damping force from drilling fluid in the lateral direction Ffb, and damping torque from fluid on bit Tfj. Forces from the formation rock at hole wall include normal force Fhy and fiiction force Fhx in X\\cy and x-directions respectively. The weight on the bit Wb is known for a given bit selection. The buoyant force Fup is due to the unbalanced force acting upon the bit. As the bit is relatively short, the buoyant force can be expressed as

Fup=GDA

where G, D, and A are pressure gradient in well bore, hole depth at the bit and crosssectional area of the drill coUar. The force / > is equal to the weight on the bit (WOB) which is dependent on the number of drill collars. Considering the static equilibrium of the bit, the force in the vertical direction can be related as follows:

Fcx=Ffx+F^p-Wj,

26

^bf

cF

-^

- = ^

^^V

rn
^
V

Figure 3.8: Free-Body Diagram of a BHA in vertical hole

^i5<- ^

V M ^ ^"- v y i ^ Vj^i M

Figure 3.9: Free-Body diagram of a bit in a vertical hole

27

The formation reactions 7/and Ffy can be calculated from analysis of the PDC bit force model presented in Chapter 2. The vertical and horizontal cutting force components from equations 2.4 and 2.6 can be written as:

2SsA^cos(T-a) Fv= ; \ ^' / 1 - sm(r - a) F^JS,A,sm(r-a) 1 - sin(r - a)

2

...(3.14)

^^^^^

where area of the cut, Ac= Or - r(r - ) sin O 0 = cos"M 1 V rJ and = cutting depth r = radius of cutting blank. The cutting torque from the formation consists of two components: cutting torque generated by the horizontal cutting forces and friction torques generated by the vertical cutting forces. The average value of the cutting torque can be expressed as

Tfa=XRiF^,^Y./'F,,R,
i=l i=l

...(3.16)

where ju is the friction coefficient between the cutter and rock. If the bit does not vibrate laterally, 7/wiU be constant and equal to 7}^. The lateral vibration of the bit in the x-y plane may result in a harmonic variation of the resultant torque 7/. Therefore, 7/can be expressed as

Tf=Tf^+Tfsm{coit)

....(3.17)

28

where 7}^ is the fluctuation in cutting torque from formation, COL is the circular frequency of lateral vibration in the x-y plane. The maximum amplitude of the fluctuation can be expressed as
^ fo = ^ f max ~ ^ fa

where the maximum torque Tfmax may depend on several factors such as weight on bit, rotary speed, rock properties, and tilt angle of the bit, etc. The resultant lateral force 7y also consists of two parts: total cutting force generated by horizontal cutting forces and friction forces generated by the vertical cutting forces. Ff=f,(FH)i^f,pi(F,)i
i=\ i=\

...(3.18)

If the cutters are arranged symmetrically in the bit face, both of these two sums are equal to zero. Otherwise, the resultant force F/has a non-zero magnitude and a changing direction because of the relative rotation of the bit with respect to the rotating x-y plane. Therefore, its major component in the j^-direction, F^, can be expressed as:

Ffy = Fjya ^Ffy^ sin(co,t)

... (3.19)

where cor represents the angular velocity of the bit relative to the wobbling plane, Ffyo is the fluctuating amplitude of the resultant cutting force in the >'-direction and can be expressed as
^ fyo = ^ fymsx ~ ^ fya

and Ffymax^^y again depend upon several factors including weight on bit, rotary speed and tilt angle of the bit. If the force F/does not act through the center of the bit face, it also exerts a torque on the bit. This torque is assumed to be negligible in the analysis.

29

The lateral force Fhy is due to the hole-wall contacting the bit. Its magnitude depends on lateral displacement of the bit and properties of the hole-wall rock. This force generates additional stresses in the neighborhood of the contact area^^. The average normal rock stress induced by the force Fhy may be approximately expressed as:

C T ; - ^

...(3.20)

The average normal strain over the contact area may be expressed as:
CT,

^r =

Er'

^r~r[^-^^z\

...(3.21)

Er

where a and a^ are the tangential and the axial stress in the formation due to the bit impact. The deformation of hole-wall rock at the contact area is equal to the lateral displacement (y^) of the bit. lDr is defined as the effective lateral depth within which the in-situ rock stress is altered due to the bit contact, then the average normal strain Sy. can be approximated as: s , ^ ^ D ^r . ...(3.22)

Substitution of equations 3.20 and 3.22 into equation 3.21 yields:

F^y=E,A,^. The tangential fiiction force is given by:

...(3.23)

Fhx=l^hv

-(^-^^)

30

The damping force F & and damping torque 7}z, are given by: y

Ffh =Cf^L

...(3.25)

and

Tfl,=c,D^A,Tdf

...(3.26)

where v/,, Db, A^ and r^/ represent the lateral velocity, bit diameter, bit surface area, and shear stress of the drilling fluid, respectively. The viscous damping coefficients c/and C/ are difficult to determine analytically. However, since their values are very small and negligible when compared to other forces, they are not taken into account in the analysis. The lateral force from the drill coUar Fcy is the reaction force oFt,y which can be determined from the deflection analysis considered later in this chapter. The torque Tc from the drill collar is the reaction torque of T^ and can be written as:

T,=T,-Tf,.

...(3.27)

The fiiction force from the well-bore Fhx generates a fiictional torque which can be estimated as Fhx Di/2. The bending moment M^fromthe drill collar can be expressed as

M,=Lj,(Ffy-Fhy)

...(3.28)

where L^ is the length of the bit and the damping force from the drilling fluid, Ffj, is neglected. Since Lj, is smaU compared to the length of drill coUar, Mc is small and negligible. 3.4 Elastic Constants of Bottom Hole Assembly 3.4.1 Static Conditions If the BHA section shown in Figure 3.8 is stationary, the BHA can be analyzed as a beam hung in a vertical hole. Then the force Ffc and torque 7}^ are equal to zero as there

31

is no rotation. The bending moment Mj, is negligible because the length of bit is small compared to that of the BHA section. Then, the linear relationship between the lateral force Fby and lateral deflection j^^ can be estabUshed. The linear relationship between the torque Tb and angular deflection OL can also be established. The proportionality coefficients in these relations are called the elastic constants. The total elastic strain energy U in the BHA section is determined by adding the terms giving the energy accompanying the work done by a bending moment, direct shear, axial force, and torsional load:

U = Uj,+Us^Ua+Ut

... (3.29)

where Ub, Ua, and Ut are the strain energies due to bending moment, axial load and torsional load, respectively. The bending moment in the BHA section is approximately given by:

M,=Fj,y(L-x)^^{L-x) = {L-x}F, by
(3.30)

M.

where L is the length of the beam (BHA assembly) and x is the distance with reference to the lowest stabilizer. Substituting equation 3.30 into equation 3.10 gives:

L{L-X)-

M, Fby + 2E,I, -dx

Ub = \
0

where Er and L are the elastic modulus and area moment of inertia of the driU collar.

32

6^c4
Neglecting the small value oMblL

M, Fby +

FI
Ub =

^E,I,

(3.31)

The shear stress in the BHA section can be approximated by:

^ ^^y xy A

(3.32)

From equation 3.7 considering shear force acting on only a single plane, the strain energy stored in an elemental length dx is given by:

U^

^xr^xS^xAxdx

. (3.33)

where js is the shear strain and Ss is the shear stress.

U. =x^xAxdx ' 2 G

... from equation 3.2

C/.=^x<lMx^.rf,

from equation3.3

Pby(^ + r) dx. AE.

.. (3.34)

33

The total strain energy can be obtained by integrating equation 3.34 from 0 to L.

U,= p ^ ^
= -^ E,A Since the gravitational force is uniformly distributed along the length of the BHA section, the axial force can be expressed as: ...(3.35)

KF

(1 + y)

Ta=w{L-x)-Ft,^

...(3.36)

where w represents the unit weight of the drill coUars and Fbx approximately equals:

Fj^^GDA.

...(3.37)

From equation 3.8 considering force acting only in the axial direction: U a =xaxsx Axx

where a and s are represent the axial stress and the axial strain. Aax

2E,

Dividing equation 3.36 by area A gives the axial stress a which upon substitution in above equation and integrating from the limits OtoL gives the total strain energy stored due to the axial force.

'^

34

 j[w^ {L - x)2 + {GDA)^ - 2w{GDL - x))^ 2E,A

0

L 2E,A

2r2

w L + {GDAY 3

-{GDA)WL

...(3.38)

From equation 3.9 for strain energy stored due to torsional load, we get U,=

sj (DI+DI) 4G D} ^ ( D | ^ ^ . ( 2_ 4G /)2 4W 5f 2
4
2

/T^2 . 7^2

2^ ir-

^D|

dx^(Di-Df)b^
4 dx (3.39)

LQ 'JZ

where J^ is the polar moment of inertia and is defmed by

32

At any radms ic, -Tb ^ R Jz Integrating equation 3.39 from 0 to L yields: Ut-\^ 0 ^^'^^
(3.40)

dx

T^L{\ + r) Ec Jz

35

The total energy Uis obtained by substituting equations 3.31, 3.35, 3.38, and 3.41 into equation3.29.

^^^^^f^,_A
6EJ,
E^A

w 2j2 L

2EcA

+ {GDAf

-{GDA)WL +

T^L{\ + r)
Ec ^ z

. (3.41)

From CastigUano's theorem (equation 3.13), differentiation equation 3.41 with respect to Fby and Tb gives the lateral deflection yi and angular deflection 6L, respectively.

yi

dU
F by

^E,L,

2{\ + r)L
EcA

Fby

...(3.42)

dU dTb

2{i + r)L
Ec Jz

(3.43)

Equations 3.42 and 3.43 can be written as:

Fbv = ksyi ly

..(3.44)

Fh = ^e ^L

...(3.45)

where ks is defmed as the elastic constant for lateral deflection and ke is defined as the elastic constant for angular deflection.

ks =

L^
3E,I,

, 2{\ + r)L
EcA

...(3.46)

36

ke=

2{\ + r)L

^'^^

(3.47)

3.4.2 Dvnamic Conditions The dynamic condition is shown in Figure 3.10 for the BHA section undergoing rotation with a constant speed. The inertia force vector E is distributed along the length of the BHA beam. Per unit length of the beam, E can be expressed as:

2.

Figure 3.10: Dynamic equilibrium of a BHA in a vertical hole

E = pAcOyy

y.rc

...(3.48)

where coy is the angular velocity of rotation of the x-y plane. The deflectionjVc results from forces Fby, Ffc, Fsx, and Fbx if buckling exists, and the inertia force vector E itself It is assumed that buckling does not occur and the initial deflection components due to Ffc and E are negligible. This assumption is vaUd only if the rotating speed and axial compression are low. If this is the case, then the lateral deflection _ c can be analyzed as a y

37

cantilever beam with a fixed load Fby at the free end of the cantilever. Consider a cantilever beam of length L and having a concentrated load F^y as shown in Figure 3.11

C
/ ^ / / / /

^v ^

Figure 3.11: Cantilever beam with an end load

The differential equation for this type of loading can be written as

EcIz^

= Fby{L-x) dx^ ^

(3.49)

The two boundary conditions are as follows: Atx = 0; dy/dx = 0 Atx = 0;y = 0 . Integrating equation 3.49 once with respect to x, we get: d ^ Ec^z - = FbyLx^Fby^ + cx where cj is the constant of integration. Applying the first boundary condition the value ocj is equal to zero,

E^I^ z = Fu^Xx - Fu., byJ^X Fby c^ dx

(3.50)

38

hitegrating equation 3.50 with respect to x, we get:

EcIzy = FbyL^~Fby^ where c^ is the constant of integration.

+ C2

...(3.51)

Applying the second boundary condition, the value of Q obtained is equal to zero. Hence
2 3

EcIzy^FbyL^-FbyFbyX^{3L-x) y=y c = ^ ^ ,

...(3.52)

Ech
Substituting equation 3.52 into equation 3.48, we get 2 Fi,yX^{3L-x) E = pAco y Eclz E = CnFb.x^{3L-x) ...(3.53)

pA)l where C = 6E,L, If the damping force from the drilling fluid is negligible, then the bending moment in the beam is generated by Fby and E. Mz =M^f~\-M^^ The inertia force vector E generates a bending moment Mze at x as shown in Figure 3.11 and its magnitude equals L ^ze = \^ E dx ~.

= \x Cn Fby X

\3L-x)dx

39

Since X =X-xnddx

=dX, the above equationbecomes L Mze = JC Fby X^ {X-x){3L-x)dX

^n^by

3L + x) V ^ ;

L'-X']=XL{L'-X'

^-x'^

..(3.54)

Strain energy due to bending is given by: 1 Uu = ^

\MI
c-z J 2EJ. 0 "

dx

L
C Z Q

Substituting M^f = Ffjy {L - x) and equation 3.54 into above equation, we get

U, =.^Cn^ " 34650

F} ' + 1 C F 2 L ' + 1 F 2 . ^y 35 " ^y 3 ^^

...(3.55)

From Castigliano's theorem: dU yi = dUh Fhy Eclz U 11 ^ ,7 2641 ^2 r\\ + Cy,L' + CtV 3 35 " 34650 (3.56)

SFby dFhy

yi = kdFby

where :^ =

Eclz '_ 11 n 2641 C^ ' + Cn L + 3 35 ^n 34650 and is defined as the dynamic elastic constant for lateral deflection.

40

3.5 Formulation of Bit Vibrations 3.5.1 Lateral Vibrations The bit is treated as a particle without any mass in the lateral motion. The equation of motion is applied in the >;-direction and the following relation is obtained: Fjy -Fcy -Fhy -(Ff,)y =m dt^ From equation 3.19, ignoring the small value oFfya, Ffy Ffy^ sm((Oyt) and substituting equaton 3.56, 3.23 and 3.25 into equation 3.57, we get ...(3.57)

FfyoSm{co,t)-kdyi-

yi-cf

dyi
dt

d
dt

yi

(3.58)

E^A ' '- + k. d yi dt^ I ^ / dyi , V L > , w dt m yi = F. m ^sm{crt)

where Fo = F, fyo-

andZ) = , the above equation becomes

) ^ + i ) + (co^f m

yi=-^sin{(s>y.t). m

..(3.59)

As the right hand side of equation 3.59 is not equal to zero, its complete solution equals the sum of the complementary solution and the particular integral. Equating the left hand side of equation 3,59 to zero, the equation is quadratic and its solution is given by:

41

1+ r /
D= Cf If ^ = m m

^E.A.^k^D,
Dj.m

r which is defined as the viscous damping factor, then equation 3.59 can be 2mo)y^

written in terms of , and .

Z)^+2^y) + y = 0

..(3.60)

and its solution is given by: Z) = - ^ y V ^ COn - n

= -4(0^+1^0)^ -^ (

(3.61)

From the roots given by equation 3.61, the complementary fimction of the differential equation 3.60 is given by

C.F = e

-^<t

C\ cos ^ll -^^c^

+C2SnU/ y - ^ y

...(3.62)

The Particular Integral is given by: F P.I = ^

m r\2

sm{co,t) D +2i^co D + a) 1 sm {co,t)

f" 2^co'D-

)^ + col

42

_Fo

\o)y,

-co'i]-24)^D D^

sm {cD^t)

co^ -CD^j -4^^o)^

FQ K -C0r]-2^C0nD \n{o)^t) sm m ( '^ 2V . ^2 " 2 )^ -)f. j -\-4g )^ j.

o)jj - o)j. Isin(2>^r)- 2 ^ )yj o)y. cos{p)y.t)

0)

n -^rf
2

'2

+ 4^

0)j^ 0)y.

If Rcos

= o)yj

-j.

'

'^

2 1

'^

y. dinRsin = 2^o)y^o)j.,ih.cn

R = ^\^^

-^rj

+4^

0)^^ ^. .

Substituting the value of 7? in the above equation, we get: F P.I = ^ [sin(y^r)cos 6 - cos(y^/)sin 6\ mR s\n{o)yt-0)
i2 2 r 2 '^ 2

m^j\o)f^ -o)j.]

+4^

o)y^ cOy s\n{cOy.t-6)

FQ s\n{p)y.t-6)
1_J^
V

2^o)y
j

cOy^m.

^n

\ + A:.

^n

EyAy

fyo
^
^

2 ^2
i2

sm {co^t-) 2^co,

+
V ^n y (3.63)

= 7/, sin(y^ - d)

43

^ fyo

where Y^ =

D.
A2 f \2 2^C0.
\ ^n j

and tan 6 =

2^0)y,CO,
CfJ COy.

OT 6 = tan

2^0) yjO)^

l_f^
C

^n

0)

rJ

n J

The term YL is the constant amplitude term and is the steady state amplitude. The complete solution of the differential equation 3.59 is the sum of equations 3.62 and 3.63 The constants defmed in equation 3.62 need to be determined based on the boundary conditions given by: At/ = 0;j^/,=j^ioand At dyL t=o = ^o where Vo is the initial linear velocity of the bit. dt Applying the first boundary condition to equation 3.62, we get yLo =<^l=>c\= VLO ' Differentiating equation 3.62 with respect to t, we get

^^-a^^e-i".dt
^o)'t

cj cosly^ -(^ o)j^) r + c^sinly^ -^ :

\2 2

c)i +
0)n COS ^^(Oj, -,

V y - ^

y sin -^y - ^ co^

'^

~^

t + C203n

-^

Applying the second boundary condition to the above equation, we get dyi dt
=^=^0= - # 0)n C\ + C2 ^C n |2

^^^
2 '2

C2

^o+^(^n
CO, n ^

yu
0)n

C2

^o^ + ^)

^o-l^

^c
C,

;Vw^ co

yVw
AA

with the assumption that ^(l + ^)/(l - ^) 1 as (f is very small. Lci o)^=o)j^ - ^ ^ ^ =>o)^ =o)yj^j\-<^'^ . (3.64)

The term o)d in the above equation is defined as the damped pseudo-natural frequency.

Substituting the values of cy and c^ in equation 3.62 and writing the final solution by adding equations 3.62 and 3.63, we get
yL=^
^<j

yio

cos{o)^t)-\-^sin{o)^t)

= j3^Io +
\<^n /

-^:^

L
\

yj^^cos{co^t)^^s\n{cOdt)
0)^

V,

ylo^
\^nj

r Let C = J : o +
\^n

\ , then the above equation becomes

j

yf^^Ce

^^^^[sin^^cos((5;^r)+cos^sin(y^r)] =Ce ^^"^

yLo ( \
Or.
O^

s\n{a)^t^\ij)
' \ yLo^n \ ^o^ J

where sin \f/ =

0)yj

,COSl//

^'

"
o.

\2

and^ = tan

ylo^

ylo^
j

\^n

\^nj

The final solution for the lateral deflection of the bit is given by

yi=Ce~^"^"

^ sin{o)dt)^YL

sin^Wyt-6).

(3.65)

Neglecting the transient state solution of equation 3.65, the steady state part of equation 3.65 gives the lateral displacement of the bit and is expressed as:

45

yi = YL sm{(o^t - e)

...(3.66)

As 0)j. approaches ty^, resonance occurs. Near resonance the magnitude Yi of the steady-state solution is a strong function of the viscous damping factor ^ and the nondimensional frequency ratio ^y^ / y . Under the resonance condition, the bit wobble causes the early failure of the PDC bit. The critical 0)r that causes resonance can be determined using the following equation: k^ + '^ ^ D,
COj.
=

(3.67)

m where kd is defmed by equation 3.56 Since the term kd is very small, it can be neglected in the above equation. The condition at resonance, then becomes

0)y

Ef.Ay Dj.m

..(3.68)

The amplitude at resonance can be determined by substituting co^ = in the term YL of equation 3.63. ^E A 'fyo
YT

^ ..(3.69)

n
2>^

= 1__^ V y

V ^ y

The denominator of above equation equals 2,^ and the amplitude Yi at resonance equals Ffyog,
f2 2go)j-m
^

where, gc is the gravitational constant for the following units;

46

Ffyo =M kd = Ibflft
Ej. = psi

Ay. =in^ D, = in

The time period at resonance equals ^njcj. 3.5.2 Angular Vibrations For a drill bit under penetrating condition, the un-balanced lateral forces acting upon the bit will cause a lateral vibration of the bit in a maximum deflection plane (x-_y plane). The unbalanced torsional loads result in the angular vibration of the bit. The bit is treated as a particle in the lateral motion and equation of motion is applied in the j^direction which yields the following differential equation:

Tc-Tjb-Tf-Fhz^ where: Fc =Ts -Tfc =Tb Tf=Tf^+TfoSn{o)Lt) Fhz = M Fhy

=I m . ^

-(S.VO)

Substitutng the above equations in equation 3.70, we get

Fh Du Ts -Tfc -Tfb -Tfa -Tf,n{coLt)-^^:^

d26 = Imxf

- ^^-^^^

But we have from the relation: T^ = Tf^ + Tf^ + Tfb Substituting this relation into equation 3.71, we get

r,siK,)-^^n=/.^
^E), dt^

-("2)

47

Considering only the steady state component ofyi, we get yi ^YiSn{o)j.t).

Substituting above equation into equation 3.72, we get

-Tf,sm{o),t)-^^^Y,sm{a),t)=I^^^^ ^^r dt

... (3.73)

rr.

jUDuEj.Aj.

Leti^ =
r

Yi, then equation 3.73 becomes: TfoSn{o)i^t)-T^sin{o)j.t) = Ijj,^ d^6, -^. dt^ ... (3.74)

Equation 3.74 is the goveming differential equation of the angular motion of the bit in the x-y plane. Integration equation 3.74 with respect to time t, we get

^ = ^^cos{o)j.t)-\-^^cos{o)f.t)-^C2
at COj. 1 yj^j^ 0)j. 1 jyij^

... (3.75)

where cs is the constant of integration. d Att = 0 ^ = 0)^, where coo is the initial angular velocity of the bit. dt Substituting this boundary condition into equation 3.75, we get: Tfo + T^
0^0 = ~ ^ + ^3 ^ ^ 3 =^0

Tfy + T^
j

d6j Tfy + r ^ ^ = 0) = 0)^ -\-

at o)j. 1 jj^-^

\ Lfo+ T^ cos(y^/j .
o)j. 1 ^-jj-

Considering the absolute angular velocity, we get

48

Tr -[-T

o) = o)r.^

0)j,I

[1 - cos(y^ t)\
mx

(3.76)

Integrating equation 3.76 with respect to time t, we get

OL =>ot + ^ ^ ^r^mx

sm {o),t) co.

+ C4

(3.77)

At /=0 <9i = 0 => C4 = 0 Hence equation 3.77 becomes

QL =o)ot +

Tfo + T^
^r^mx

\n{o)f.t) sm
0),

...(3.78)

The angular velocity and angular displacement of the bit motion due to the un-balanced torsional loads are given by equations 3.76 and 3.78, respectively.

49

CHAPTER 4 BIT WOBBLING-CALCULATIONS, RESULTS AND DISCUSSION

4.1 Examnle Calculations The following basic input parameters shown in Table 4.1 are considered for analyzing the bit wobbling model. Based on these parameters, sensitivity analysis is also carried out to determine the various factors that influence bit wobbling.

Table 4.1: Basic Input Parameters for bit wobbling analysis No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Descriptioii Location of the bottom stabihzer from bit, L friner diameter of the bottom drill collar, D Outer diameter of the bottom drill collar, d Young's Modulus of the drill coUar, Ec Bit diameter, D/, Weightofbit, Wb Bit lateral contact area to formation rock, Ar Young's Modulus of the formation rock, Er Effective depth of rock deformation, Dr Friction coeffcient between bit and rock, ^ Rotary Speed, A'^ Viscous Damping Factor, ^ Variation in cutting force, Ffyo Variation in cutting torque, Tfa Magnitude 60 ft 2.5-in 6.25-in 3x10' psi 7.875-in 96 Ib lin^ 5x10''psi 4ft 0.3 60RPM 0.5 600 Ib 25 Ib-ft

Density of steel considered, p = 490.0 Ibm/ft Cross-sectional areaof drill coIlar,/ = - ( D ^ -d^]= -(6.25^ - 2 . 5 ^ )= 25.7708/^

50

T V

2nN

2X;TX60

Initial angular velocity = o)o= 60

= 60

= 6.2832 rad/sec.

AreaMomentoflnertia, /^ = ( D ^ - ^ " ^ 1 = ( 6 . 2 5 ^ - 2 . 5 " ^ ) / ? ' ^ = 0.0035197//"^. 64 ^ ^ 64 ^ ^12^

From equation 3.53; C = T";;~ft

6E,I,
Writing the above equation in terms of individual units, we get pAcol
^n

i ^ Ibm . . 2 V .-V

fi

, A

1 1

6 ^c ^z

6 yfi

jV

144, vsec j ^ Ibf 144^ /^' J

V./"

fi 2

1 1

Ibm

6 144^ /6/ /^ sec^ ^c

^ /r"^ =2.496134 X10"^/r"^ 6 x 144^ x 32.2

Hence,C = 2.496134x10"^ x
' ^ 6c/z

^ft'^

...(4.1)

Substituting the known values into equation 4.1, we get

3x10^x0.0035197

From equation 3.56, k^ = 3 35 "

EJz
34650 "

51

If the units ofEc, L, Cn, and L are psi,ft'',ft'\ Ibf/ft, then

andft, respectively, and the unit of ^rf is

k^=^

\44EJ,
11 + " 3 35 C^ 34650 ^n

Ibflft

(4.2)

'

Substituting the given values in kd, we get

kd 60 3 35

144x3x10' xO.0035197

= 3.0721 Ibflft

+ 1.178x10-^ x 6 0 ^ + ^ ^ ( l . 1 7 8 x 1 0 - ^ ^ x 6 0 ^ ^
34650

Fromy =

checking for the units, we get

Ibf Ibm ft

Ibm ft ibf sec^

sec

deglsec.

(4.3)

Substituting the given values in above equation, we get ^5x10^x1

(y,

+ 3.0721 x32.2 = 647.5 deglsec^ 11.301 radlsec. 96

52

The viscous damping factor is dimensionless and is given by < = ; - . Writing this ^ 2 m 0): equation in terms of individual units, we get

^f 2 m y

_ Ibf -scc ft

\ Ibm

1 1 \ ^sec^
1 A

_lbf - sec Ibmft

Ibm ft Ibf-scc^

rx<?ImcOyj

..(4.4)

2mo)r.

From the given data, the value of < is equal to 0.5 f

Ej.Aj.

'fyo

-\-k.

At resonance, Y^ =

\ ~ ^

from equation 3.63

2#

Substituting the given values in above equation, we get

Ej.Ay

'fi'O
Yj =

+ k.

600/

^5x10^x1 2x0.5

3.0721 = 4.8 x l O " V = 0.00576/.

2cC0r ^ n From tan 6 = ,, , at resonance d =

COyi -cOy ^

Substituting the values of YL and 6 in the steady state term of equation 3.65, we get the following relation Yi = 0.00576 xsin 641.5t
2

...(4.5)

53

The mass moment of inertia, Imx assuming the bit as a sphere is given by: lyy,^ =~Ma^ =-mD^ = - x 9 6 x - ^ = 4.\34 Ibmft^ 5 5 ^ 5 144x4 ^
_ _ juDi.Ej.Aj. ^^

tvom 1^=

Yi, writmg m terms of individual units, we get

r Ibf ftx^^xin T =

, 2

'^^

^ft=lbfft

Rcncc. T.,=^^^^^Y,ft ' -"w

2D,

(4.6)

Substituting the individual values in T^, we get 0.3x^^x5x10^x1 12 x 4.8x10 = 59.0625 Ibfft T =
2x4

From equation 3.76, we have

6i =o)^t +

Tfo +^w
^r^mx

m{o)y.t) t- sm
0),

(4.7)

Each term in the right hand side of equation 4.7 should be dimensionless. Considering the dimensions of the second term in the above equation we get: Ibf-ft
^ X

1 Ibm- ft

f1 ^secy

X sec =

Ibf-scc^ Ibm - ft

54

Introducing the gravitational constant, gc in the above equation we get: Ibf - sec ^ Ibf - sec ^ Ibm - ft ~Ti T~ ^gc = ~ X T = dimensionless Ibm-ft Ibm-ft ibf-sQC^ Hence equation 4.7 re-arranged with the proper units becomes:

6i =o)ot-\-

^Tfo -\-T^^ g<

\
^r^mx

sm {o),t)
0),

...(4.8)

Substituting the given values in equation 4.8, we get:

6J =2nt-^

(25 + 59.0625)x32.2 t '647.5x4.134

647.5

sin(647.5/) ^

= 6.2832-17.7622 -1.5444xl0"-'sm in(647.5r)J.

(4.9)

4.2 Results and Discusson From equation 3.63, it is observed that resonance occurs when thefirequencyratio \^y. IcOyj I is equal to unit in the Yi term. Using equation 3.66 and substituting the values, the lateral displacement of the bit is plotted with time as the parameter under resonance condition. The corresponding data for all the figures shown in this section is enclosed in Appendix A. The path of the bit center is shown in Figure 4.1. The plot indicates that the bit undergoes a wobbling motion. As a result of this motion, a lobed pattem of the bottom hole is observed when resonance occurs. The maximum amplitude of vibration at resonance is calculated to be 0.00576-zn for the given conditions. For non-resonance conditions, Figures 4.2 and 4.3 indicate the path of bit center for frequency ratios of less than one and greater than one, respectively.

55

0.008

O.OOB

o.ooa

0.008

Figure 4.1: Path of bit center at resonance condition

Figure 4.2: Path of bit center at non-resonance condition (Frequency ratio=0.88)

56

. oa

-0.008-^

Figure 4.3: Path of bit center at non-resonance condition (Frequency ratio=1.30) The effect of lateral vibration amplitude with fi'equency ratio for a given viscous damping factor is shown in Figure 4.4. Figure 4.5 shows the variation of amplitude ratio (ratio of the observed amplitude to the amplitude at resonance condition) with frequency ratio. The variation of phase angle with frequency ratio and damping factor is shown in Figure 4.6.

0.4

0.6

0.8

1.2

1.4

FrequAncy Ratio (wr/Wn*)

Figure 4.4: Variation of AmpUtude with Frequency Ratio

57

2.8 2.82.425 2.0o

/ "0.2

\ -O.D

e l^
ro tE:

-1.0 M.6 t=2J

s.

1.6 u 1.4tL

1.0 1 1^^ 0.8 0.6 OA ' 0,2 0.0 - , ,

j
1

---^.^.^.lE^O.O^^''*"*''''*^,,,,..^
'^'"--^'^^^
"-"fc..^.^^^^^^ **,

^N^

0.2

0.4

0.6

0.8 1 15 Frequency Ratio (wrAn/n*)

1.4

1.6

1.8

Figure 4.5: Variation of Amplitude Ratio with Frequency Ratio

180
160

0.0

0.5

1.0

1 Fre<|uency ratio (wr/wn')

2.0

Figure 4.6: Variation of Phase Angle with Frequency Ratio

58

The amplitude ratio is given by: Amplitude Ratio =

2 ^2 / A

. (4.10) 1_^
V

+
j

2^co,
K ^n j

(l-r^f+(2^ry

^n

The foUowing observations^^ can be made from Figures 4.5 and 4.6: 1. For an un-damped system, the viscous damping factor is equal to zero and the amplitude ratio becomes -. -.

2. The damping reduces the amplitude ratio for all the values of the frequency ratio. 3. The reduction of the amplitude ratio in the presence of damping is very significant at or near resonance. 4. The maximum amplitude ratio is obtained by differentiating equation 4.10 with respect to r and equating the resulting equation to zero.
-3/

d(A.R)
^
=

-1
X

[\-r^J+{2^rf
2^^ =1-/-^ ^r

2\\-r

)(-2r) + 8#^r = 0

dr

= Vl-2^'
...(4.11)

0).

= co'J\-2^^

The damped frequency Or is less than the un-damped natural frequency o)y^ from equation 4.11 and also less than the damped natural frequency defined by equation 3.64, i.e. o)^ =o)yj^j\-<^ 5. The maximum value of the ampUtude ratio when r = -yl - 2 ^ is given by Amplitude Ratio = 1

4 ^
59

The above equation can be used to determine the amount of damping present in a system if the maximum amplitude of the response is measured. Conversely, if the magnitude of damping in a system is known, an estimate of the maximum amplitude of vibration can be made. 6. Below resonance, the phase angle increases with increase in damping. Above resonance, the phase angle decreases with increase in damping. Brett et al. concluded that the failure of PDC cutters in hard rock drilling is due to cutter chipping (impacts from vibrations). Cutter chipping occurs when the cutter moves backward due to bit wobbling. Figure 4.7 shows the schematic of the bit face. The wobbling motion of the bit in the bit-face plane can be resolved into two motions, i.e., lateral and rotational motion. hi Figure 4.7, thick arrows represent cutter velocities in the lateral motion of the bit, while thin arrows represent cutter velocities in the rotational motion of the bit. The vector sum of velocities due to these two motions is the total velocity of the cutter. At points B, C, and D, the magnitudes of the total velocities are greater than the magnitudes of their component velocities. At point^, the magnitude of the total velocity is less than that of its component velocities. The cutter velocity at point A can either be a forward velocity or be a backward velocity depending upon the magnitude of the velocities due to the lateral and rotational motion. If the magnitude of the velocity due to lateral motion is greater than that of the velocity due to rotation, the cutter at point A will have a backward velocity. This backward velocity may cause cutter chipping if the formation rock is hard. Taking derivative of the steady state part of equation 3.65, the lateral velocity of the bit center is obtained and given by:

Vc = h ^r cos{o)j.t-(^).

... (4.12)

The rotational velocity of the cutter at a distance rl from the bit center is given by: Vryc=co^ ...(4.13)

60

Figure 4.7: Cutter Velocities on a PDC bit face Source: "Bit Wobble: A Kinematic Interpretation of PDC Bit Failure" SPEPaper 28313^^ which is the velocity relative to the bit center. The total forward velocity of a cutter located between point A and the bit center can be found out from the following relation:

K=Vrl/c-~V,.

...(4.14)

If Vr is negative, the cutter has a backward velocity. Equations 4.13 and 4.14 indicate that the rotary speed has a positive effect on reducing the backward cutter velocity. Since bit rotation has no effect on the velocity of a cutter located at the bit center, the backward velocity of a cutter at bit center is higher than that of other cutters. It is usually found from field observations that the cutters near the bit center are more severely chipped than other cutters. Using the given data, the total forward velocity Vr is plotted versus time and shown in Figure 4.8. The plot indicates that the cutter at the bit center will move forward and backward for the same amount of time. Figure 4.9 is a similar plot but for a harder formation. Although the magnitude of backward velocity is lower compared to that of a

61

softer formation, the frequency of the vibration is increased in this case. Hence in hard formation drilling, more cutter chipping is expected.
0.20

0.00

0.01

0.02

0.03

0.04

0.05 Time (sec)

0.06

0.07

0.08

0.09

0.10

Figure 4.8: Velocity of cutter at bit center (Er = 5x\0^psi)

0.15

0.00

0.01

0.02

0.03

0.04

0.05 Tme (sec)

0.06

0.10

Figure 4.9: Velocity of cutter at bit center ( * = IxlO^ psi) ^ To minimize cutter failure of PDC bits, it is necessary to analyze the factors affecting the backward velocities of the cutters. The pseudo-natural circular frequency is given by:

62

0),

(4.15)

If the stabiUzer position is high, then the value okd will be low and the pseudonatural frequency is dependent mainly on the formation rock property Er- It is also observed that the drill-string vibration is sensitive to the lithology of the formation being drilled. The effect of lateral contact area on backward cutter velocity at bit center is shown in Figure 4.10. This plot indicates that the backward cutter velocity can be effectively reduced by increasing the lateral contact area of the bit. This is in fact put into practice in field by utiUzing a wider low friction pad.

0.80 (Frequency Ratio = 0.5, Damping Factor = 0.5) OJO

0.60 J" 0.50

o 0.40

>
L.

0.30 0.20 0.10 0.00 3 4 5 6 7 8 9 Lateral Conact Area, in**2

Figure 4.10: Effect of Lateral Contact Area on Cutter Backward Velocity The effect of weight of bit on backward cutter velocity is shown in Figure 4.11. From the plot it is observed that a heavy bit is better than a lighter bit for controlling backward cutter velocity. The effect of stabilizer position on backward cutter velocity is

63

shown in Figure 4.12. It is observed that the nearer the stabilizer is to the bit, the lower the backward cutter velocity can be achieved.
0.50

50

100

150

200

250

300

360

400

450

600

WeightofBit(lbf)

Figure 4.11: Effect of Weight of Bit on Cutter Backward Velocity

0.18 0.16
u
01 tfl

0.14 -

/ / / / /

0.12

o 0.10 -

>

4>

S 0.08 0.06 0.04 0.02 0.00 1

1

10

20

30 Stabllzer dstance from Bit, ft

40

60

60

Figure 4.12: Effect of Stabilizer position on Cutter Backward Velocity

64

Figure 4.13 shows the effect of drill-collar stiffness on backward cutter velocity indicating that increasing drilI-coUar stiffness reduces backward cutter velocity when the stabilizer is placed close to the bit. The effect of viscous damping factor on backward cutter velocity is shown in Figure 4.14. It indicates that viscous drilling fluids are helpful in reducing the cutter backward velocity.
0,16

0.15 ^ Dhrahc-e of Stsbiliaer from Sit = 5 ft

0.14 0.13

Distance of Stabliserfrom B i t 3 ft

Drill-Coliar Stlffnss { x +7 ibf/in^)

Figure 4.13: Effect of DriII CoIIar Stifftiess on Cutter Backward Velocity

0.6

0.8 Damping Factor

1.6

Figure 4.14: Effect of Viscous Damping Factor on Cutter Backward Velocity

65

CHAPTER 5 DRILL-STRING BUCKLING: GENERALIZED ANALYTICAL SOLUTION

For analyzing the drill-string buckling, both the ends of the drill-string are considered hinged. As a result, there are reactions at both the ends which in tum have both vertical and horizontal components. There are also reactions of the wall at the points where the buckled pipe contacts the wall. The drilling string is assumed as a continuous pipe with no tool joints.

Figure 5.1: Extemal forces acting upon a Drilling String Source: Arthur Lubinski^"^ Study ofBuckling ofRotary Drilling Strings, 1950. The extemal forces acting on the drilling string are shown in Figure 5.1 in which: 1. The upward force Wi is the reaction at the top hinged end. 2. The upward force W2 is the vertical component of the reaction of the bottom of the hole on the drilling string and represents the "weight on bit." 3. The force F2 is the horizontal component of the reaction of the bottom of the hole on the drilling string.

66

4. The horizontal force F} is the reaction of the wall of the hole on the drilling string if the pipe is buckled. Two additional forces not shown in the above figure are the weight of the pipe which is a vertical downward force, and the buoyancy which is a vertical upward force, both appUed at the center of gravity of the drilling string. The influence of viscous forces on the drill-string and the jet forces on the bit are neglected as they are small when compared to the weight on the bit. When W^^Q, there is no weight on the bit and the drilling string is straight resulting in an elastic equilibrium. If a lateral force is applied and a small deflection is produced, this deflection disappears when the lateral force is removed and the pipe becomes straight again. If W2 is increased, but maintained below a certain critical value, the straight form remains stable. If the critical value of W2 is reached, the straight form of the pipe becomes unstable; i.e., if a lateral force, however small is appUed and a small deflection is produced, this deflection does not disappear when the lateral force is removed. On the contrary, the deflection increases until a bent form of stable equilibrium known as buckling is reached. The Xaxis is defined as the axis of the hole and taken to be positive downwards. The point of origin is defined as the neutral point. The 7axis is taken as positive to the right. The plane of theXand Faxes is the plane of smallest flexural rigidity in which the buckling occurs. The units of X and Y are in feet. The bending moment Mof the buckled string expressed in units oflbfft can be given by: d^Y M =E I ^ dX^ ...(5.1)

where E is the Young's Modulus of elasticity of steel and/is the moment of inertia of the cross section. The units oE and /are Ibf/ft^ and//'^, respectively. The rate of change of the bending moment is defined as the shear force and is obtained by differentiating equation 5.1 with respect to X.

dh
F,=EI^ dX^ 67 ...(5.2)

The shear forces along any cross section of the drilling string, such as MNin Figure 5.1 can be determined and substituted in equation 5.2 from which the bending moment M can be obtained by integration. The forces acting on the portion of the string MN are represented vectorially in Figure 5.2. The weight of the drilling string below the section MN is represented by W and the buoyant force due to the drilling mud is represented by force B}. The hydrostatic pressure B2 does not act upon the section MN and hence this must be vectorially subtracted from the buoyant force B} to get the tme buoyancy. Since the considered section of the drilling string is in equilibrium, the sum of all forces equals to zero. As shown in Figure 5.3, AB is the weight on the bit; BC is the horizontal component of the reaction of the bottom of the hole, or Ff, CD is the weight W of the part of the string located under MN\ DE is the buoyancy force Bj\ and EF is the buoyancy force B2.

^N

Figure 5.2: Extemal Forces acting on a drilling string section Source: Arthur Lubinski^"^ - Study ofBuckling ofRotary Drilling Strings, 1950.

68

M.

"J
B C

^N

Figure 5.3: Vectorial representation of forces on a drilling string section Source: Arthur Lubinski^"* - Study ofBuckling ofRotary Drilling Strings, 1950. In the initial analysis, the effect of force F is not considered and set equal to zero to simplify the analysis. From constmction of Figure 5.3, the force FA which represents the reaction of that part of the drilling string above MN on the portion below. This force has two components: FG is the shearing force and GA is the compressive or tensile force according to its direction. The vector CD represents the actual weight of the drill-string section and DE represents the buoyant force due to the drilling mud. For determining the shear forces, the different forces shown in Figure 5.3 are resolved along MN. The vectorial equation is represented by:

AB-\-BC-\-CE-\-EF-\-FG + GA = 0 and the projection of all the vectors along the axis MN is given by:

. (5.3)

ABsina-

BCcosa-CEsina

-FG = 0

(5.4)

The shearing force FG is given by:

FG = {AB -

CE)sma-BCcosa

. (5.5)

69

Under actual conditions in the hole, the angle a is very small. Therefore cos a=\ and sin a = tan a. Then, equation 5.5 reduces to

FG =

{AB-CE)\'xia-BC

(5.6)

The buoyancy factor is given by:

r B.F = \
Pmud

\ ...(5.7)

\Psteel j

Letjo represent the weight of the drilling string in mud (units olbflft) which is equal to the product of the actual weight of the drilling string in air and equation 5.7. LetXy and X2 designate, respectively, the values of X for the two ends of the drilling string. Then:

X,=Xo =

W, P W2 (5.8)

Equation 5.5 can be re-written as follows:

F, = [W2-p{X2

-X)tana]-F2

(5.9)

Substituting in equation 5.9 the value 0X2 from equation 5.8 and replacing tan a with -dYldX, we get: F, =-pX -F2 ' dX ^ (5.10)

70

Substituting equation 5.10 into equation 5.2, we get

d^Y dY EI- + pX + F2=0 dX^ dX

...(5.11)

Equation 5.11 represents the differential equation of the buckled drilling string. Let

X = mx

...(5.12)

and

Y = my

...(5.13)

where m is a constant which will be defined later. We have from above two equations

dY _dy dX dx

(5.14)

d^Y _ 1 d^y dX^ m dx^

...(5.15)

d^Y ^ 1 d^y dX^ m^ dx^

(5.16)

Substituting equations 5.12, 5.14, and 5.16 into equation 5.11, we get

d y p 3 dy F2 2 r\ ^ + m^x + m ^O j;^3 EJ dx EI

c< \n\ ... (5.17)

71

The value of m is chosen such that

3 EI m^ = Let cbedefinedas: Fo c = -^ pm Substituting equations 5.18 and 5.19 into equation 5.17, we get

...(5.18)

...(5.19)

^ +x ^ +c=0 dx^ dx Substituting equations 5.15 and 5.18 into equation 5.1, we get

...(5.20)

,2

M = pm^f dx^

...(5.21)

Equation 5.18 shows that m is expressed inft and equations 5.12, 5.13, 5.14, 5.19, and 5.21 show that;:,,)^, dyldx^ (^yldx ^ and c are dimensionless. Consequently, the analysis made with these factors will be altogether general and independent of the drilling string and drilling fluid. The solution to the differential equation defmed by equation 5.21 and shown below is required. d y dy . f+ J + c = 0 C dx^ dx

Let

z=^ dx

...(5.22)

72

Substituting equation 5.22 into the above differential equation, we get

dh_
dx

+ xz + c = 0

...(5.23)

The solution to equation 5.23 can be expressed in terms of a power series defined by:

00

z= ^ a x " .
=0

...(5.24)

Substituting equation 5.24 into equation 5.23, we get

00

X ( - l ) o x " - ^ + ^fl;c"-^^+c = 0.
=0 =0

7Z-2

(5.25)

Equation 5.25 is a polynomial fimction in powers of x and satisfies for any value ox. If this is tme then the coefficients of x'^, x\ x ^ x^, etc. must all be equal to zero. Coefficient of x Coefficient of .x Coefficient of x Coefficient of x Coefficient of x'^ Coefficient of x"^ Coefficient of x'^
2^2 + c = 0 => 32 -

^2

aQ + 2.3^3 = 0 => 3 = -ao_ 2.3 ai +3.4^4 = 0 => 4 = - fL 3.4 2 + 4.5(35 = 0 =^ 5 = - ^2 4.5 ^3 + 5.6^5 = 0 => a^ = 4 + 6.7^7 = 0 => ay = 5 +7.8^8 =0=> ag =
^

2.4.5

^3 ^O 5.6 = 2.3.5.6
^4

6.1 a^ 7.8

3.4.6.7 c 2.4.5.7.8

73

Substituting the above coefficients into equation 5.25, we get

^O

^l

^]

z = ao+atX 2
0

x^

^x^ 2.3

^-x^ + x^ + ^x'' + x' 3.4 2.4.5 2.3.5.6 3.4.6.7

x + 2.4.5.7.8

1 - ^ + 2.3 2.3.5.6 , x' x' 1 4.5 + 4.5.7.8

2.3.5.6.8.9

+ ... + aix 1

3.4

3.4.6.7

3.4.6.7.9.10

^x' 2

4.5.7.8.10.11 +

..(5.26)

z = ^ = aF(x)-\-bG(x) + cH(x) dx

...(5.27)

where F(x), G(x), and H(x) are the terms within brackets as defined in equation 5.26 Integrating equation 5.27, gives ..(5.28)

y = aS(x) + bT(x)-\-cU(x)-\-g

Differentiating equation 5.27 gives

d^ dx^

= aP(x) + bQ(x) + cR(x)

(5.29)

The fiinctions in equafions 5.27, 5.28, and 5.29 are defined as foUows: F{x) = \- + "" 2.3 2.3.5.6

2.3.5.6.8.9

(5.30)

G(x) = X

, x' x' 1 3.4 + 3.4.6.7

3.4.6.7.9.10

+ ...

(5.31)

74

, x' x' H(x) = - ~ 1 4.5 + 4.5.7.8 2

4.5.7.8.10.11 + .,

(5.32)

S(x) = X

, x' x' 1 2.3.4 + 2.3.5.6.7 1 2 x' x' + 3.4.6.7.8 3.4.5

2.3.5.6.8.9.10 + ..,

..(5.33)

T(x) = X

3.4.6.7.9.10.11 +

(5.34)

U(x) = -

4.5.6 + 4.5.7.8.9

4.5.7.8.10.11.12 +

. (5.35)

P(x) = -

, I

x' x' + 3.5 3.5.6.8

3.5.6.8,9.11

...(5.36)

Q(x) = \-^+
3

3.4.6

3.4.6.7.9 + ...

(5.37)

6
X

R(x) = -X

1 2.4 + 2.4.5.7

2.4.5.7.8.10 +

(5.38)

The fiinction values for equations from 5.31 through 5.38 have been calculated by writing computer program using MATLAB. The computer source code is enclosed in B-1 of Appendix B. The curves generated for above fianctions are plotted in dimensionless units and are shown in Figures 5.4, 5.5, and 5.6, respectively. These curves can be used as reference for calculating the deflections once the equation coefficients are determined.

75

-M

Figure 5.4: Functions of F(x), P(x), and S(x)

Figure 5.5: Functions of G(x), Q(x), and T(x)

76

Figure 5.5: Functions ofH(x), R(x), and U(x)

77

CHAPTER 6 DRILL-STRING BUCKLING - ANALYSIS AND DISCUSSION

6.1 Critical Buckling Condition of the First Order Let X} and x^ designate the values of x for the upper and lower ends of the drilling string respectively. The distance X} represents the distance between the neutral point and the top of the hole. The distance x^ represents the distance between the bit and neutral point. Let P}, Q}, R}, Sj etc. denote the values of P(jc), Q(x), R(x), S(x), etc, at x=X} and Pi Qi Ri S2, etc, denote the values of P(x), Q(x), R(x), S(x), etc, at x=X2. As both the ends of the drilling string are hinged, the bending moments at these two ends are equal to zero. From equations 5.21 and 5.29, we get aPi+bQi-\-cRi =0 ...(6.1)

aP2-\-bQ2-\-cR2

=0.

(6.2)

At both the ends, y=0 and equation 5.28 gives for both the ends: aSi-\-bTi-\-cUi-\-g =0 . (6.3)

aS2-^bT2-\-cU2-\-g

=0

..(6.4)

Eliminating g from equations 5.41 and 5.42, we get a{Si-S2)^b{T^-T2) + c{U^-U2)=0 ...(6.5)

Equations 6.1, 6.2, and 6.5 together yield the relationship between X} and x^ for buckling to occur. This is obtained by eliminating the coefficients and equating the determinant to zero. ^i Pl {8,-82) i Ql {TI-T2) ^i ^2 {UI-U2) (6.6)

78

Equation 6.6 is solved by iteratively using computer program and the values of x/ and X2 determined. These values are plotted and shown in Figure 6.1. The computer source code for determining the solution is enclosed in B.2 of Appendix B.
X2, Dlmensionless Units -S.O -7.5 -7.0 -G.5

\ \ \ \ ,

e.o
-6.5 -6.0 -4.5 -4.0 -3.5 -3.0 -2.5 -2.0 -1.6 -1.0 -0.5 0.0

sN .
\, ^> \ sl\

N
^ ^

~. ~

1.80 1,85 1.90 1S5 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70

Figure 6.1: Critical Condition of the First-Order From Figure 6.1, it is observed that when the absolute value of x; is small, i.e., when the hole is very shallow, the pipe requires a larger weight on the bit in order to buckle. When the hole is deeper, the critical value of the weight on the bit decreases and approaches asymptotically to a certain value. Under actual drilling conditions, xy is very large and the value of x^ is equal to its asymptotic limit. As seen from Figure 6.1, the asymptotic limit is reached when the value of x; is equal to -6.0 and the corresponding value of X2 is equal to 1.94. Hence, it may be considered with negligible error that X2=1.94 is the critical condition of the first-order. The critical length of stands of pipe stacked vertically in the derrick can be obtained by referring to Figure 6.1. The critical length corresponds to the condition when x/=0 and the corresponding value of X2=2.65. The critical buckling of the first-order was investigated in Chapter 5 and it was found that at this condition, the distance x^ between the bit and the neutral point is equal

79

to 1.94 dimensionless units. From equation 5.18, the length in feet of one dimensional unit equals: m = 3, EI .,.(6.7)

The weight, in Ibs of the length of the drilling string equal to one dimensionless unit equals: mp = ^^EIp (6.8)

The critical length of the driUing string for critical buckling of the first order is obtained by multiplying equation 6.8 with 1.94. Figure 6.2 shows the plot of length in feet of one dimensionless unit for different drill-pipes and drill-collars with change in drilling mud density.

10

12

20

Flujd Dens ty (Ibm/gai)

Figure 6.2: Length of a dimensionless unit with change in driUing mud density From the above figure, it is observed that as the drilling fluid density increases, the length of one dimensionless unit also increases. However, the increase in length is not great enough when compared with the length of the drilling string, AIso, for a given

80

drilling fluid density, the range of length of one-dimensionless unit for drill-pipe or drillcollars is very small. Hence, for analysis purpose, it can be assumed that the length of one-dimensionless unit for drill-pipe is approximately the same for both drill-pipe and drill-coUar. The critical weight on bit for critical buckling of the first-order is obtained by using equation 6.2. The critical weights on bit for first-order critical buckling are plotted and shown in Figure 6.3. From Figure 6.3, it is observed that heavier the mud, the smaller are the critical weights on the bit. However, the influence of the drill fluid density on buckling is not very significant.
14000 1 DC;7.0"O4),3.0"l.D | 12000

10000

1 DC: 6.25** OS), 2^5" W

==*.

-^.=^

o
^ 6000 |DP:4^"bj).3.826"I.D
11

DP; 2.875" OJ), 2.151" 1.0

4000

.,

1 DC 4.75" OJ), 1^75" LO |

1 DP: 5.5" 0,D, 4,67" U) |

''""'

2000

.-.8 10 12 {ibm/^3\) 14 16 18 20

riuld Density

Figure 6,3: Critical Weights on bit for First-Order Critical Buckling Drill-Strings used for drilling are usually a combination of drill-pipes and driUcoUars, and hence their combined effect must be taken into account when analyzing buckling. Two different scenarios are possible with this combination. One scenario is where the neutral point is assumed to be located in the drill-pipe and the other scenario considers the neutral point to be located in the drill-collars. Considering the first scenario, the critical weight on the bit in this case will be equal to the weight of the drill collars and the portion of the drill pipe below the neutral point. If the length of the driU coUars is represented by Zc, then the length of the collars in dimensionless units is given by LJm.

81

For critical conditions of the first-order, the length in dimensionless units of the portion of the driU-pipe below the neutral point is given by: \.94-Ljm. ...(6.9)

The weights of these two portions in the presence of drilling fluid are LcPc and (l .94 - L^ /m)m Pp, respectively. The sum of the weights equal to the weight W} and equals: Wi=L,(p,-pp)+\.94mpp. ...(6.10)

From equation 6.10, it is observed that the critical weights are linearfiinctionsof the total length of the drill-collars. The slope of the straight line and the>'-intercept being equal to Pc-Pp and \.94mpp, respectively. This is represented by the inclined line in Figure 6.4. For the second scenario, the whole weight on the bit is given by the drill collars. The critical values of the weight on bit cannot be increased by adding more drill coUars. The second scenario corresponds to the horizontal Une of Figure 6.4. The dotted lines in Figure 6.4 represent similar conditions in the presence of higher drilling fluid density. From Figure 6.4 to prevent first-order buckling in the presence of 10 Ibm/gal drilling fluid, the weight on the bit should not exceed 8600 Ibs. In the presence of 16 Ibm/gal drilling fluid, the weight on bit should not exceed 7800 Ibs. If the weight on bit exceeds these values, then the drill string will buckle once until the weight on bit exceeds 16600 and 15400 Ibs, respectively, when the drill string will buckle a second time. The critical weight on the bit can be increased by using drill-collars with bigger size, high stifftiess and elasticity values. Figure 6.5 shows the effect of driU coUar size on first order buckling with a radial clearance of 2.75-in. between the hole and the drill collar and in the presence of 12.0 Ibm/gal drilling mud. The drill collar inside diameter is taken as 1.875-in. It is observed that the critical weight on the bit increases as the drill collar size increases. This is due to the increase in stifftiess of the drill collars with increasing size. Similar plots are shown in Figures 6.6 and 6.7 for drill collar inside diameters of 2.5-in and 3.0-in, respectively. As 82

the driU collar inside diameter increases, the critical weight on bit also increases and similar profiles as in Figure 6.5 are observed.
Drll-Ppe: 4,5-in, 16.6 Ib/ft. Drll-Collar: 6.25-ln O.D,2.25-in LD.S.S Ib/ft 18000
lOlbm/galMud

16000 14000 12000

/ / / / /
//

'

16lbm/galMud

Drjlllng Strng Buckled Once

c o 8000
/ ' /

lOlbm/galMud

/'/
16lbm/galMud

6000 4000 2000

/ / ' //'

Straight Drlling String

'\

10

12

14

16

18

20

Number of Drll Coflars

Figure 6.4: Buckling Conditions for Combination Drilling Strings

16000 14000 12000
10000
* y ^
15

! 1 m\ Denslty: 12.0 Ibm/gal Oearance: 2.7S-in. Dr^Cotar 1.0:1.875-111.

120

105 90 X

t o

-75

8000

60 w g

x: o

6000

4000 2000

30
'C

15

3.0

3.5

4.0

4.5

5.0 5.5 6.0 OrillCoIlarO.D, in.

6.5

7.0

7.5

8.0

Figure 6.5: Influence of DrilI-CoIIar size on Buckling (I.D=1.875-z^)

83

20000 180<K) --_ 16000 m 14000 m 120CK)

1 1 Mud D e n s ^ : 12.0 mmS^l Clearmtce: 2.7S~n. DrCo^rLD:2.S-in

150

136

^ Z ^^

120 105

c o

-py^

90

U. lOOW

6000 4<m
20 ._

' ' ..^"""'''''^

E
7.0 7.5 8,0 8.5

76 60 45 30 16

36 .

4.0

4.5

5.0

5.5

6.0

6.5

Drill Coilar O.D, in

Figure 6.6: Influence of DriII-CoIIar size on Buckling (l.D=2.5~in)

60000

240

Mud e n ^ : 12.0 Ibm/gal Cfe^tGe: 2.7S'n. DriOrfafrl.D:3.0.in.

5(K)00

200 n

i
4<K)00 c: o

^ -

<
o 160 X o m o 120 c 80

1 3)00

~~ .

j L._

20000

10000

40

5.0

53

6.0

6.5

7J0

7.5

S.O

B3

9.0

B3

10.0

10.5

11J)

11.5

12.0

DriHCoHarO.D, in

Figure 6.7: Influence of DrilI-CoIIar size on Buckling (LD=3.0-z>2)

84

6.1.1 Point of Tangencv for First-Order Critical Condition Let the point of contact where the drill-string contacts the bore-hole wall be represented in feet by J G and in dimensionless units by x^. Atx=X3, the slope dy/dx=0 and S from equation 5.27, we get aF^-\-bG2-\-cH^ =0. ...(6.11)

As the bending moments at the ends are equal to zero, equations 5.39 and 5.40 can be used along with equation 6.5. aPi-\-bQi-\-cRi =0 ... (6.12)

aP2+bQ2+cR2

=0.

...(6.13)

The above three equations have possible solutions if the following determinant equals zero.
F3 G3 H3
^l Qi Rx

...(6.14)

Pl Qi Ri

The above equation gives the relation between x^ at the point of tangency and X} and x^ at the end of the strings for critical condition. But at critical condition of first order, X}=-6.0 and X2=\ .94. Hence the corresponding value of xj for which the determinant given by equation 6.14 is equal to zero gives the value ofxs. The computer source code for determining the value oxs is enclosed in B.3 of Appendix B. The value ofxs thus obtained is equal to 0.145.

6.1.2 Equation Coefficients for First-Order Critical Condition In order to determine the shape of the buckled string axis, the distribution of bending moments, etc, the values of a, b, and c from equations 6.1, 6.2, and 6.5 needs to be determined. But it is observed that indeterminate values of these factors are obtained from these equations. This is because the bending moment defined by equation 5.21 is

85

vaUd only for smaU deflections. AIso, when the drill-string contacts the bore-hole wall, further buckling is stopped until the weight on the bit is increased to a new critical value, Hence, in order to remove the indeterminacy, at the point of tangency the deflection is taken equal to the apparent radius of the hole. The apparent radius of the hole is defined by the following relation. r = ^{D-D,) ...(6.15)

and

r = ^{D-D,)

...(6.16)

where D is the diameter of the hole, D^ is the outside diameter of the driU collars, and A is the outside diameter of the tool joints. Hence, aXx=X3, Y=r and according to equation 5.13, j^=r/m. Equation 5.28 gives 5 3 + 6 r 3 + c t / 3 + g = . m ...(6,17)

At the lower end of the string, the deflection is zero, i.e., forx=X2=1.94, y=0. Hence, equation 5.28 gives aS2-\-bT2-\-cU2-^g = 0. ...(6.18)

Eliminating g between equations 6.17 and 6.18 and rewriting equations 6.1 and 6.2, we get ^(^3 -Si)^b{T^ -Ti)+c{U^ -Ui) = ... (6.19)

aPi-\-bQi-\-cRi

=0

...(6.1)

aP2-\-bQ2-\-cR2 = 0 .

... (6.2)

86

Substitutmgxy=-6.0, X2=\.94, andxi=0.145 in the above equations, the values oa(m/r), b(m/r), and c(m/r) can be calculated. From equations 6.1 and 6.2, we get a QxRi -QiRi ^ _ ^

~ R\P2 -RiP\ ~ PiQi -PiQi

a = 9l^lzQAc
P\Q2-P2Q\

...(6.20)

^^R^PIZMLC.

...(6.21)

^102-^201

Substituting equations 6.14 and 6.15 into equation 6.13 gives: c = X . m (5 _s^)Q^^2-Q2R\ ^ ( y _T^f\P2 -R2P\ ^ ( ^ _ ^ ) ^Pl2-^2l ^Pl2-^2a ...(6.22)

6.2 Critical Buckling Conditions above First-Order After the drill string undergoes first-order buckling and if the weight on the bit goes on increasing, there is a tendency for the drill string to buckle a second time. In such a situation, the differential equation defined by equation 5.11 does not hold true for the whole length of the drilling string. For the upper portion of the drilling string (located above the point of tangency), the force F which is the reaction of the wall of the hole against the pipe needs to be considered. Hence, equation 5.11 is modified as: d^Y dY E I ^ + pX + F2-F = 0. dX^ dX ^ The equations 5.19 and 5.23 are also modified as follows: c = ^^/^ pm ...(6.24) ...(6.23)

87

and

d'^z ^ j c z + ci =0. Jx^

...(6.25)

The integration of equations 5.23 and 6.25 gives the same kind of general solution, i.e., equations 5.27, 5.28, and 5.29. However, not only c but also the integration constants a, b, and g become different for the lower and upper portions of the drilling string. The constants y, 67, c/ and a^, b^, c^ refer to the upper and lower portions of the drilling strings above the tangency point. The equations for the upper portion can be written as:

y = aiS{x)-\-biT{x)-\-ciU{x)-\-gl

... (6.26)

^ = aiF(x) + 6iG(x)+ci//(x) dx

... (6.27)

^ = aiP{x) + biQ{x) + ciR{x). dx^

... (6.28)

The value of cj = F^ /pm . The corresponding equations for the lower portion can be written as:

y = a28{x)+b2T{x) + C2U{x)+g2

...(6.29)

^ = a2F{x)+b2G{x)+C2H{x) dx ^ = a2P{x)-^b2Q{x) + C2R{x). dx 2 The value of c^ = F^ /pm 88

2

... (6.30)

...(6.31)

Let X} correspond to the upper end of the drilling string as previously stated and value of xy=6.0. Let x^ correspond to the lower end of the drilling string, and X3 to the point at which the pipe is tangent to the wall of the hole. The three boundary conditions for the upper portion of the drilling string are as follows: 1. The bending moment is equal to zero at the upper end of the string which leads to equation 6.32. 2. At x=X3, the slope is equal to zero which leads to equation 6.33. 3. Atx=xy, the deflectionj;=0. 4. At x=X3, the deflection j ; is equal to the apparent radius of the hole, i.e., y=r/m. The third and fourth boundary conditions when substituted into equation 6.26, give two expressions from which upon elimination of g, equation 6.34 is obtained. The three boundary conditions for the lower portion of the string are same as for the upper portion of the string which leads to equations 6.35, 6.36, and 6.37, respectively. One additional boundary condition is that at x=jC5, the bending moments are equal. Hence, equations 6.28 and 6.31, we get equation 6.38. The equations are as follows:

aiPi + biQx + cii?i = 0

... (6.32)

^1^3 + 61G3 + C1//3 = 0

... (6.33)

l f e - ^ l ) + ^l(^3-^l)+q(^3-t^l) = -

...(6.34)

2^2+^202+^2^2=0

...(6.35)

2^3 -^b^Gi^ +C2//3 = 0 a2{S^-S2)^b2{T^-T2) + C2{U^-U2)--

... (6,36) ...(6.37)

89

1^3 +^103 + q ^ 3 -2^3 ~hQ2> -^2^3 = 0

...(6.38)

The above seven equations have possible solutions only if their determinant equals zero. This condition shown in equation 6.39 in which xy=-6.0 gives the relationship between x^ and X3. The values of x^ and X3 calculated using this equation is shown in Table 6.1. The computer source code for calculating the value of Xi when the second buckle contacts the bore-hole wall is enclosed in B.4 of Appendix B. The computer source code for calculating the different values of x^ and X3 using equation 6.39 is enclosed in B.5 of Appendix B.

^i Q\ F^ C^ {8^-8,){T,-T,)

0 0 0
^3

0 0 0
3

Ri H^ (f/3-/i) 0
0 0
^3

0 0 0

0 0 0

0 0 2

P2 P3 {82-82) -P3

R2 H3 {U3-U2) -R3

0 r m 0
0

0 ...(6.39)

G3 {T3-T2) -Q3

L 'H

Table 6.1: Values of x^ andxj for Critical Condition above First Order
x2
1.94000 2.00000 2.30000 2.60000 3.20000 3.50000 3.75300 4.00000 4.21800

x3
0.14450 0.21710 0.58020 0.94280 1.66650 2.03080 2.34470 2.67100 3.08550

x2-x3 1.79550 1.78290 1.71980 1.65720 1.53350 1.46920 1.40830 1.32900 1.13250

90

6.2.1 Equation Coefficients for Crtical Conditions above Frst-Order The values of x^ andxj obtained from Table 6.1 are substituted into equations 6.32 through 6.37 and the value of the equations coefficients determined are by solving the simultaneous equations. For determining the equations coefficients for the upper portion of the string, we have 1 QlH^ - G3R1 bi i?iF3 - P1//3 ci P1G3 - F^Qi . (6.40)

Q,H,-G,R, P1G2-F2Q1

RlFj-P^H^ b\ = -zrTr^i P1G3 - F^Qx

,^ .r.. (6-42)

Substituting equations 6.41 and 6.42 into equation 6.34 gives: ci=X . ...(6.43)

m ^ _^^QiH3z^^(T " P.G^-F^Q,

_T)MlzMl + {u^_U,) 'P\G3-F3Qx

For the lower portion of the string, from equations 6.35 and 6.36, we get: ^2 = ^2 = ^^ Q2H2 - G2R2 R2P3 - P2H3 P2G3 - F3Q2 (6.44)

Q2H3-G2R2
flT = Cj

.....
...(6.45)

^2^3-^302

MIZM^C^. ^2^3-^302

...(6.46)

Substituting equations 6.45 and 6.46 into equation 6.37 gives:

91

6.3 Shape of the Buckled DrlUng String Let the deflection coefficient h be defined by the following equation: h=y. r From equations 6.48 and 5.13, we get Y = hr. ...(6.49) ...(6.48)

From above equations, h is equal to unity for the deflection Y equal to the apparent radius of the hole r. At the upper end of the string above the tangency point the deflection is zero and equation 6.26 gives 0 = aiSi + bxTi + cit/i + g i . ... (6.50)

EUminatinggy between equations 6.26 and 6.50, we get:

y = a^{S-8^)+b^{T-T^)+c^{U-U^).

...(6.51)

At the lower end of the strng, the deflection is equal to zero and equation 6.29 gives:

0=

fl2'^2+^2^2+C2t^2+^2^

...(6.52)

Eliminating g2 between equations 6.23 and 6.52 gives:

y = a2{8-82)+b2{T-T2)+C2{U-U2).

...(6.53)

92

The values of the equation coefficients for the upper and lower portions of the drilling string calculated eariier can be substituted into equations 6.51 and 6.52 to give the deflectionj/ at each value of x. The shape of the buckled drilling string has been obtained forxy=-6.0 and forx2=1.94, 3.753, and 4.218, respectively. The distancex2-x represents the distance above the bit and the shape of the buckled drilling string is shown on a plot of y versus x^-x in Figure 6.8. It has been determined by iterative process that at X2=4.219; the second buckle contacts the wall of the hole. As the length of one-dimensionless unit does not vary much from one type of driUing string to another, the shape of any buckled drilling string is almost the same for any order of buckling. However, in case of a drill-pipe, it corresponds to a much lesser weight on the bit. As the weight on the bit increases between the first-order and second-order, the shape of the buckled string changes and at a particular weight on bit above the critical weight of the second order, the drill string buckles again and contacts the wall of the hole at two points. Comparison of these buckled curves indicate that the portion of the strng located close to the bit is deflected more, while the portion located above the tangency point is progressively straight.
+1-

* *
*> c

-3.0

1.0

-03

0.0

0.5

1.0

D^flectjon. y (Dimensionldss unjt$)

Figure 6.8: Shape of Buckled Curves for Different Buckling Orders 93

A plot of X2-Xi versus x^ is obtained and shown in Figure 6.9. The data for this plot is obtained from Table 6.1. From this figure, the change of shape of the buckled curves and varation in position of the neutral and tangency points can be easily visualized
4.0

Critlcal
3.0

Crtical Condtion Second Order

i>

1
>
^ ' "

Condition First Ord*r

Second Buckle Contcts Wall

c
41

>'
,-''
y

f I 2.0
* .2
f f r t'

^'

1.0

/ /
^'
y
j i

'

0.0

.-' *
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

5,0

x , Distane betwftn Bit and Neutral Point. Dmensioniess units

Figure 6.9: Tangency and Neutral Points Variation with different Buckling Orders In Figure 6.9, the abscissa represents the distance between the bit and the neutral point in dimensionless units. The curve represents the varation of the distance between the bit and the tangency point which is taken as the ordinate. In order to determine the relative position of the point of tangency with respect to the neutral point, a dashed straight line is drawn at an angle of 45 degrees with respect to the coordinate axis. The ordinate of any point on this dashed line indicates the distance between the bit and the neutral point. The vertical distance between the curve and the dashed line indicates the distance between the tangency and the neutral points. It is observed from the figure that, as the weight on the bit goes on increasing or the distance x^ goes on increasing, the distance between the tangency and the neutral points goes on increasing and the distance between the bit and tangency point goes on decreasing. In other words, as the weight on the bit increases, the neutral point moves upwards and the tangency point moves

94

downwards. The downward displacement of the tangency point becomes much faster when the weight on the bit is increased between the critical value of the second-order and the weight for which the second buckle contacts the wall of the hole. It is also observed that at higher buckling orders the highest buckle contacts the wall of the hole at the neutral point; and that, as the weight on the bit is increased, the point of tangency is slightly displaced downward while the neutral point moves rapidly upward. Knowledge of the location of the tangency point may be usefiil when drilling hard formation below a soft and caving shale. If less weight than the critical weight of the first-order is used while drilling in the caving shale in order to avoid caving and once the hard formation is encountered, then the weight on the bit should not be increased immediately. If the weight on the bit is increased immediately, the drilling string will contact the caving shale wall above and caving could occur. One-and-half-dimensional units should be drilled before weight on bit is increased and at that time, the weight on bit should be increased immediately rather than progressively in order to obtain a tangency point in the hard formation. It is observed that, drilling should be carried with a weight on the bit corresponding to approximately 3.75 dimensionless units between the bit and the neutral point but should not exceed 4.22 dimensionless units in order to keep the second buckle from contacting the caving shale above. Higher values of weight on bit should not be used before 4.2 dimensionless units of the hard formation are drilled. The crtical weight for buckling of the second-order to occur is obtained by multiplying equation 6.8 by 3.753 units. Figure 6.10 shows the crtical weight on bit for second order buckling for different drll pipes and drill collars. The magnitude of the critical weights is higher than the corresponding weights of the first order buckling. As the drlling fluid density increases, the crtical weight on bits decreases. However, the decrease is very small when compared with the change in the drlling fluid density. The computer source code for calculating the deflections of the buckled drlling strng at each position is enclosed in B.6 of Appendix B.

95

14000

2000

Figure 6.10: Crtical Weights on Bit for Second-Order Buckling

6.4 Bending Moment Diagrams for First and Higher-Buckling Orders When the drilling strng buckles, each cross section becomes subjected to a bending moment generating a tensile stress on one side and a compressive stress on the other side. As the drilling strng rotates, these stresses are reversed in each rotation cycle and can lead to fatigue loading of the drlling strng materal. Let the bending moment coefficient be defined by: d y m
i =

...(6.54)

dx^ r

By eliminating Sy/do^ from equation 6.54 and 5.21, we get M =i pmr. ...(6.55)

For any given size of drll-pipe or drU collars, equation 6.55 indicates that the bending moment increases with increase in the apparent radius of the hole. If the size of the hole is constant, then the bending moment is directiy proportional to the bending coefficient /. Substituting the equation coefficients values into equations 6.28 and 6.31 96

and using equation 6.54, we get a relation between the bending moment coefficient and distance x. The data thus obtained is plotted and shown in Figures 6.11, 6.12, and 6.13 for first-order buckling, second-order buckling, and when the second buckle contacts the bore hole wall, respectively. From Figure 6.11, it is observed that the bending moment coefficient has two points at which the bending moment is a maximum. The larger of these two is found to be closer to the bit. A similar pattem is observed in Figures 6.12 and 6.13, and it is observed that the maximum bending moment occurs near the bit and is least at points farthest from the bit. In Figures 6.12 and 6.13, a discontinuity is observed in the profile at a point where the strng contacts the wall of the hole which appUes a lateral load on the strng. There is no discontinuity of the bending moment coefficient at which the second buckle contacts the wall of the hole, because there is no lateral load applied to the string at this point. The points where the bending moments are zero indicate points of high shear stress forces acting on the drilling strings. The computer source code for calculating the deflections of the buckled drilling string at each position is enclosed in B.6 of Appendix B.

&"
T

.t:
6_
X
*-'

l l sl c ^ . S ?I

54-

^ /

4-

"

"''
0.0 0.5 1.0 1.5 2.0

-2.0

-1.5

1.0

-0.5

Bendng Moment Coetficlent i iDimensionless unltsf

Figure 6.11: Bending Moment Coefficient Profile for First-Order Buckling

97

f4-]
y_

'
C

8-^
f-^

* i .t:

T c

? =
o **

Jr

si .1
C tf

Ij^

4-

...-f^

** '

"
'1.5 1.0 -0.5 0.0

0.5

1.0

B e n d i n g M o m e n t Coeff c i e n t . I (Dmen$onless u n i t s )

Figure 6.12: Bending Moment Coefficient Profile for Second-Order Buckling

m_ ! =

> l

ll s.i
C X X iA

-2.0

1.5

-1.0

-0.5

0.0

B e n d i n g ivioment C o e f f i c e n t I ( D i m e n s o n l e s s unitsf

Figure 6.13: Bending Moment Coefficient Profile: Second buckle contacts bore-hole waU

98

6.5 Force AppUed bv Buckled Drill-String on bore-hole wall The reaction F of the wall of the hole on the buckled drilling string is equal to: F = F2-Fi. ...(6.56)

Substituting the values ofF} and F2 from the value of cy and C2 given in equations 6.28 and 6.31, we get F = pr ^ m V r m^ r j (6.57)

If the term within brackets in equation 6.57 is defined as the coefficient/, we get F = fpr. ...(6.58)

The force coefficient/is a fimction of cy and c^ and hence depends on the distance between the bit and the neutral point. This distance is also proportional to the weight on the bit. The variation of/with the distance in dimensionless units between the bit and neutral point is shown in Figure 6.14. The computer source code for calculating the force coefficient/is enclosed in B.5 of Appendix B. When the weight on the bit progressively increases and the weight on bit reaches the critical condition of the first order, the coefficient and, consequently the force F is equal to zero. This is because, when buckling is on the verge of occurring, the sUghtest increase in the rigidity of the pipe would prevent it. Similarly, if it occurs, the sUghtest force can stop it and the reaction of the wall of the hole on the buckled string is zero. As the weight on the bit becomes greater than the critical value, the coefficient/ and consequently the force Fincreases. The greatest value of/at which the second buckle contacts the wall of the hole is found to be 2.7 from the figure. The greatest magnitude of the force is found by substituting the value of/into equation 6.58, i.e.,

F = 2.7 pr

...(6.59)

99

3.0

P' Second
auc ie

2.5

ContactsWall

c S 1.6

Critical Condition Second Order

1,0

Chtical Conditlon ' Frst Order

0.5

0.0 0.0 0.5 1.0 1.5

II/ 2,0

23 3.0 3.5 4.0 4.5

X2, Dimensionless Untts Distance between Bit and Neutrai Point

Figure 6.14: Coefficient/for calculating force on bore-hole wall due to drill string buckling
500

10

20

30

40

50

60

iO

$0

100

Actuol Hole Dimeter. in.

Figure 6.15: Force of Buckled Drilling String (Second Buckle Contacts Bore Hole Wall)

100

The values of the force F given by equation 6.59 is plotted in Figure 6.15 for various sizes of drill pipe and drill coUars in a drilling mud of 12 Ibm/gal density. From the figure it is observed that the magnitude of this force is not very high when compared to the weight on the bit. It is also found out that in most formations the hole remains straight in spite of the buckled strings. However, if the formation has a tendency to cave, the rate at which the cave grows accelerates because the force involved increases with the diameter of the cave.

101

CHAPTER 7 CONCLUSIONS AND RECOMMENDATIONS

A PDC "bit-wobbling" model has been developed and analyzed for both lateral and angular vibrations. Resonance is responsible for severe bit wobbling which may damage PDC bits rapidly in hard formation drilling. Resonant frequency is very sensitive to rock properties. The amplitude of bit vibration at both resonance and non-resonance conditions has been determined. The factors that influence the backward cutter velocity have been determined. The rotational motion of the bit is inversely proportional to the backward cutter velocity and it is observed that the cutters located at the bit center tend to chip out and wear more. As the rock becomes harder, the vibration amplitude reduces and the frequency of vibration increases. The lateral bit contact area, damping factor, drillcollar stiffiiess and bit weight are inversely proportional to the backward cutter velocity. The backward cutter velocity is highly sensitive to the stabiUzer length within 10 feet, and beyond a length of 10 feet the backward velocity stabilizes to a constant value. It is recommended that the stabilizer be placed as close to the bit as possible to prevent buildup of large vibration amplitudes. The present model can befiartherrefined by conducting field tests and correlating the experimental results with the theoretical results obtained from this study. The effect of drilling parameters such as weight on bit and rotary speed, on the backward cutter velocity which cannot be analyzed using the present model can be incorporated as fixture study in this area. Further work can also include determination of the critical rotary speeds and fluctuation amplitudes of the cutting forces and cutting torque. The effect of shear forces only at the bottom of the BHA has been considered for determining the static and dynamic elastic constants. The effect of other forces such as the axial forces, bending moments and torques acting on the top and bottom of the BHA and their effect on the BHA elastic constants can be taken as a further study.

102

The differential equation for drilling-string buckling has been developed and its analytical solution determined. The critical values of weight on bit at which the first and higher order buckling occur have been determined. It is observed that the length of one-dimensionless unit for first-order buckling is almost the same for a drill-pipe and drilI-coUar. The critical weight on bit reduces as the drilling fluid density increases for a given size of drill-pipe and drilI-coUar. The regions within which the magnitude of the weight on bit can be set to prevent buckling have been determined. It is also observed that the magnitude of the force acting on the bore-hole wall when the second buckle contacts the bore-hole wall is very small. This force is directly proportional to the apparent radius of the hole and tends to increase while drilling in a caving formation. The shapes of the buckled drilling string for different buckling orders have been determined. The point of tangency for different buckling orders also has been determined which gives insight into the depth at which the weight on the bit needs to be applied when a hard formation is encountered. Further study in this area includes determining the buckling conditions and buckled shapes for higher buckling orders above two. As drill-strings are subjected to combined reversed bending stresses due to its rotation that causes fatigue failure, the effect of fatigue on the strength of a drill-string and its buckling can be studied. The effect of a drilling string having varying sections of material properties and its combined effect on buckling can be studied. The effect of drill-pipe vibration on buckling can also be taken up as further study.

103

REFERENCES

1.

Brett, J.F., Warren, T.M., and Behr, S.M.: "Bit Whirl: A New Theory of PDC Bit Failure," SPE DriUing Eng., December 1990. Winters, W.J.: "Roller-Bit Model with Rock Ductihty and Cone Offset," paper SPE 16696 presented at the SPE Annual Technical Conference and Exhibition, Dallas, September 27-30, 1987. Oniya, E.C.: "Relationships between Formation Strength, Drilling Strength, and Electric Log Properties," Paper SPE 18166 presented at the SPE Annual Technical Conference and exhibition, Houston, October 2-5, 1988. Glowka, D.A, and Stone, C.M.: "Effects of Thermal and Mechanical Loading on PDC Bit Life," SPEDE; Trans., AIME, 281, June 1986 Zijsling, D.H.: "Analysis of Temperature Distribution and Performance of PDC Bits under Field Drilling Conditions," Paper SPE 13260 presented at the SPE Annual Technical Conference and Exhibition, Houston, September 16-19, 1984. Warren, T.M. and Sinor, L.A.: "Drag -Bit Wear Model," SPEDE; Trans., AIME, 287, June 1989 Warren, T.M. and Sinor, L.A.: "Drag-Bit Performance Modeling," SPEDE 119-27; Trans. AIME, 287, June 1989 Brett, J.F., Warren, T.M., and Behr, S.M.: "Bit Whiri: A New Theory of PDC Bit Failure," Paper SPE 19571 presented at the SPE Annual Technical Conference and Exhibition, San Antonio, October 8-11, 1989. Brett, J.F., Warren, T.M., and Sinor, L.A.: "Development of a Whiri-Resistant Bit," SPE Drilling Eng, December 1990.

2.

3.

4.

5.

6.

7.

8.

9.

10. Boyun Guo and Geir Hareland: "Bit Wobble: A Kinetic hiterpretation of PDC Bit Failure," Paper SPE 28313 presented at the SPE Annual Technical Conference and Exhibition, New Orleans, September 25-28, 1994. 11. Huang, Tseng and Dareing, D.W.: "Buckling and Lateral Vibration of Drill Pipe," ASME Paper No. 68-Pet. 31 presented at the Petroleum Mechanical Engineering and First Pressure Vessels and Piping Conference, Dallas, Texas, September 22-25, 1968.

104

12. Huang, Tseng and Dareing, D. W.: "Buckling and Frequencies of Long Vertical Pipes," proceedings of the American Society of Civil Engineers, Vol. 95, No. EMl, pp. 167-181, February 1969. 13. Baryshnikov, A., Calderoni, A., Ligrone, A., Ferrara, P., and Agip, S. P. A., " A New Approach to the Analysis of Drilling String Fatigue Behavior," SPE 30524 presented at the SPE Annual Technical Conference and Exhibition, Dallas, Oct. 22-25, 1998 14. Arthur Lubinski,: "A Study of the Buckling of Rotary Drilling Strings," presented at the SPE Spring Meeting, Mid-Continent District, Division of Production, Oklahoma City, Marchl950. 15. Black, H. Paul.: Theory ofMetal Cutting, McGraw-Hill Book Company, Inc, New York, 1961. 16. Burr, H.. Arthur, Cheatham, B. John.: Mechanical Analysis andDesign, Second Edition, Easter Economy Edition, Prentice-Hall India, New Delhi, 1999. 17. Khurmi, R. S.: 8trength ofMaterials, Twenty-First Edition, S. Chand and Company Ltd., 1990. 18. Rao, S. Singiresu.: Mechanical Vibrations, Addison-Wesley Pubhshing Company, Reading,MA, 1985.

105

APPENDIX A BIT WOBBLING DATA

106

o c

>

Freq. Ratio Si = 0 4 . 0056 .070 0054 .074 Si = 0 6 . Si = 0 8 . Si = 1.0 Si = 1.2 Si = 1.4 Si = 1.6

Si = 0 0 .

Si = 0 2 .

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
2699000

t i-H

H t o
00 II

Si = 2 0 .

2.0

cs! cq '^ m cp

0056 .070 0.005813 0057 .099 0067 .025 0063 .076 0072 .041 0082 .047 0090 .090 0.011959 0.014150 0.014400 0072 . 2 4 9 0.011814 .086 0.013091 0 0 8 4 .067 0084 .038 0066 0060 . 0 0 0 0.005183 0040 . 0 6 8 0.004154 0039 . 0 6 2 0.003416 .088 0034 .008 0026 .048 0.002571 0 0 2 4 0020 . 0 2 7 0.002119 0.001920 0.001855

0056 .070 0059 .079 0.005918 0.006120 0060 .048 0067 .076 0070 .020 0070 .065 0074 .084 0073 .075 0070 .020 0066 .037 0055 .044 0.004615 0030 .095 0032 .034 0025 .084 0027 .044 0.002163 0.001907 0.001694

0056 .070 0057 .076 0.005821 0058 .086 0055 .094 0059 .097 0057 .099 0.005861 0.005618 0055 .023 0040 .080 0040 .039 0032 .085 0037 .037 0027 .097 0022 .068 0022 .038 0.002071 0.001851 0.001662 0.001499

0056 .070 0.005703 0.005538 .024 0059 .059 0058 0055 .044 0046 .096 .068 0.005253 0 0 4 0 0049 . 0 9 2 0.004235 .086 0048 .060 0036 0.004332 0.003512 0036 . 0 9 6 0.003182 .080 0030 .060 0028 .066 0.003250 0 0 2 0 0022 . 0 9 4 0.002361 0022 . 0 6 8 0.002141 0026 . 0 3 4 0.001946 0.002129 0.001772 0.001921 0.001618 0.001739 0.001481 0.001579 0.001358 0.001438 0.001249 0.001313 0.001152

0056 .070 0055 .064 0.005367 0046 .094 0.004515 0047 .000 0.003655 0.003281 0024 .099 0025 .066 0020 .040 0.002175 0.001977 0.001803 0.001648 0.001511 0.001390 0.001281 0.001184 0.001096 0.001018

0056 .070 0059 .059 0.005183 0.004651 0.004114 0032 .067 0030 .024 0024 .084 0023 .059 0027 .029 0025 .007 0.001866 0.001700 0.001555 0.001427 0.001314 0.001214 0.001125 0.001044 0007 .092 0000 .097

0056 .070 0.005536 0049 .092 0045 .035 0036 .072 0036 .020 0024 .086 0020 .057 0022 .028 0.001996 0.001800 0.001633 0.001490 0.001366 0.001257 0.001161 0.001076 0.001000 0003 .092 0007 .081 0.000815

9960000

107

0056 .070 0.005818 0060 .000 0063 .030 0065 .087 0078 .060 0090 .000 0.011294 0.016000 0.030316

o -

0056 .070 0056 .048 0040 .080 0047 .009 0035 .045 0025 .094 0.002557 0024 .020 0.001985 0.001775 0.001600 0.001453 0.001326 0.001218 0.001123 0.001039 0009 .089 0004 .080 0008 .077 0003 .078

h-^ 00 CT>

0056 .070 0059 .034 0040 .069 0032 .085 0.003187 0029 .067 0.002319 0022 .004 0.001789 0.001598 0.001440 0.001308 0.001195 0.001098 0.001014 0004 .090 0007 .084 0.000816 0006 .074 0.000717 0007 .064

(D

C D

;-i

<D

a
Si = 0 8 . Si = 1.0 Si = 1.2 Si = 1.4 Si = 1.6 Si = 1.8

Freq. Ratio Si = 0 2 .
o q o q o q

Si = 0 0 .

Si = 0 4 .

Si = 0 6 .

Si = 2 0 .

00 .0 0.10 02 .0 03 .0 04 .0 05 .0 06 .0 07 .0 08 .0 09 .0
o q

27 .8 52 .6
*

o q

q
co q

q q q q q

q
CM

q q

CD

o
CO

i^ 00 05
CSj

C 5 co 5

co

CM

CNI

co cq cq

CM

q
CD

CD

108
in
CM

1.10 0.95 08 .0 06 .8 05 .8 05 .0 04 .3 03 .8 0.33 02 .9

20 .0

o q
^

o o o o o o o o oq q q CSI cq 51:

47 .6 2.27 1.45 1.04 08 .0 06 .4 0.53 04 .5 03 .8 0.33

20 .8 24 .6 25 .0 20 .5 1.54 1.16 09 .0 07 .2 0.59 05 .0 0.43 03 .7 0.32

09 .8 0.91 08 .3 07 .5 06 .6 05 .9 0.52 04 .6 04 .0 03 .6 0.32 02 .9 02 .6

1.00 1.00 09 .9 0.97 09 .5 0.91 08 .7 0.81 0.75 06 .9 06 .3 05 .6 0.51 04 .6 0.41 0.37 03 .3 03 .0 0.27 0.25 02 .3

1.00 09 .9 09 .6 09 .2 08 .6 08 .0 07 .4 06 .7 0.61 0.55 05 .0 04 .5 0.41 03 .7 03 .4 0.31 02 .8 02 .6 02 .4 0.22 02 .0

1.00 09 .8 0.93 08 .6 0.78 0.71 06 .3 05 .7 0.51 04 .6 04 .2 03 .8 03 .4 0.31 02 .9 02 .6 02 .4 0.22 0.21 0.19 0.18

1.00 09 .7 09 .0 0.81 0.71 06 .3 05 .6 04 .9 04 .4 04 .0 03 .6 03 .2 0.30 02 .7 0.25 02 .3 0.21 02 .0 0.18 0.17 0.16

1.00 09 .6 08 .7 07 .6 06 .5 05 .7 04 .9 04 .4 03 .9 0.35 0.31 02 .8 02 .6 02 .4 02 .2 02 .0 0.19 0.17 0.16 0.15 0.14

1.00 09 .5 08 .3 0.71 06 .0 0.51 04 .4 03 .9 03 .4 0.31 02 .8 02 .5 0.23 0.21 0.19 0.18 0.17 0.16 0.15 0.14 0.13

1.00 09 .4 08 .0 06 .6 0.55 04 .7 04 .0 0.35 0.31 02 .8 02 .5 0.23 0.21 0.19 0.18 0.16 0.15 0.14 0.13 0.12 0.12

Table A.3. Variation of Phase Angle with Frequency Ratio (Phase Angle in degrees)

Freq. Ratio

Si = 0.05

Si = 0.25

Si = 0.1

Si = 0.5

Si = 1.0

Si = 2.0

Si = 3.0

Si = 4.0

Si = 5.0

00 . 01 . 02 . 03 . 04 . 05 . 06 . 07 . 08 . 09 . 10 . 11 . 12 . 13 . 14 . 15 . 16 . 17 . 18 . 19 . 2.0 21 . 2.2 2.3 2.4 2.5 26 . 2.7 2.8 29 . 30 .

0 1 1 2 3 4 5 8 13 25 90 152 165 169 172 173 174 175 175 176 176 176 177 177 177 177 177 178 178 178 178

0 3 6 9 13 18 25 34 48 67 90 111 126 137 144 149 153 156 158 160 162 163 164 165 166 167 167 168 168 169 169

0 1 2 4 5 8 11 15 24 43 90 134 151 159 164 167 168 170 171 172 172 173 173 174 174 175 175 175 175 176 176

0 6 12 18 25 34 43 54 66 78 90 101 110 118 124 130 134 138 141 144 146 148 150 152 153 155 156 157 158 159 159

0 11 23 33 44 53 62 70 77 84 90 95 100 105 109 113 116 119 122 124 127 129 131 133 135 136 138 139 141 142 143

0 22 40 53 62 69 75 80 84 87 90 93 95 98 100 102 104 106 107 109 111 112 114 115 116 118 119 120 121 123 124

0 31 51 63 71 76 80 83 86 88 90 92 93 95 97 98 99 100 102 103 104 105 106 107 108 109 110 111 112 113 114

0 42 62 71 77 81 83 85 87 89 90 91 92 93 94 95 96 97 98 99 99 100 101 102 102 103 104 105 105 106 107

0 45 64 73 78 81 84 86 87 89 90 91 92 93 94 95 96 96 97 98 99 99 100 101 101 102 102 103 104 104 105

109

Table A.4. Cutter Velocity at Bit Center (Er = 5x\&psi)

Time (sec) 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01 0.011 0.012 0.013 0.014 0.015 0.016 0.017 0.018 0.019 0.02 0.021 0.022 0.023 0.024 0.025 0.026 0.027 0.028 0.029 0.03 0.031 0.032 0.033

Velocity (ft/sec) -0.1115 -0.0639 -0.0096 0.0456 0.0962 0.1367 0.1630 0.1724 0.1639 0.1383 0.0984 0.0483 -0.0069 -0.0613 -0.1094 -0.1461 -0.1676 -0.1717 -0.1580 -0.1278 -0.0844 -0.0322 0.0234 0.0765 0.1217 0.1542 0.1707 0.1695 0.1507 0.1162 0.0696 0.0158 -0.0396 -0.0909

Time (sec) 0.034 0.035 0.036 0.037 0.038 0.039 0.04 0.041 0.042 0.043 0.044 0.045 0.046 0.047 0.048 0.049 0.05 0.051 0.052 0.053 0.054 0.055 0.056 0.057 0.058 0.059 0.06 0.061 0.062 0.063 0.064 0.065 0.066 0.067

Velocity (ft/sec) -0.1328 -0.1609 -0.1722 -0.1657 -0.1419 -0.1034 -0.0542 0.0007 0.0555 0.1045 0.1427 0.1661 0.1722 0.1604 0.1319 0.0898 0.0383 -0.0172 -0.0709 -0.1172 -0.1513 -0.1697 -0.1705 -0.1536 -0.1207 -0.0752 -0.0220 0.0335 0.0856 0.1288 0.1585 0.1718 0.1673 0.1454

Time (sec) 0.068 0.069 0.07 0.071 0.072 0.073 0.074 0.075 0.076 0.077 0.078 0.079 0.08 0.081 0.082 0.083 0.084 0.085 0.086 0.087 0.088 0.089 0.09 0.091 0.092 0.093 0.094 0.095 0.096 0.097 0.098 0.099 0.1

Velocity (ft/sec) 0.1083 0.0600 0.0055 -0.0496 -0.0995 -0.1391 -0.1643 -0.1724 -0.1625 -0.1358 -0.0950 -0.0443 0.0110 0.0652 0.1126 0.1483 0.1685 0.1713 0.1563 0.1250 0.0808 0.0281 -0.0274 -0.0802 -0.1245 -0.1560 -0.1712 -0.1687 -0.1486 -0.1131 -0.0658 -0.0117 0.0436

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Table A.5. Cutter Velocity at Bit Center (Er = \y.\0'psi)

Time (sec)
0.0000 0.0005 0.0010 0.0015 0.0020 0.0025 0.0030 0.0035 0.0040 0.0045 0.0050 0.0055 0.0060 0.0065 0.0070 0.0075 0.0080 0.0085 0.0090 0.0095 0.0100 0.0105 0.0110 0.0115 0.0120 0.0125 0.0130 0.0135 0.0140 0.0145 0.0150 0.0155 0.0160 0.0165 0.0170 0.0175 0.0180 0.0185 0.0190 0.0195 0.0200

Vel. (ft/sec) -0.079 -0.030 0.026 0.076 0.110 0.122 0.109 0.073 0.022 -0.033 -0.082 -0.113 -0.122 -0.105 -0.066 -0.014 0.041 0.087 0.116 0.121 0.101 0.060 0.007 -0.048 -0.092 -0.118 -0.119 -0.096 -0.053 0.001 0.055 0.097 0.120 0.118 0.091 0.046 -0.009 -0.062 -0.102 -0.121 -0.115

Time (sec) 0.0205 0.0210 0.0215 0.0220 0.0225 0.0230 0.0235 0.0240 0.0245 0.0250 0.0255 0.0260 0.0265 0.0270 0.0275 0.0280 0.0285 0.0290 0.0295 0.0300 0.0305 0.0310 0.0315 0.0320 0.0325 0.0330 0.0335 0.0340 0.0345 0.0350 0.0355 0.0360 0.0365 0.0370 0.0375 0.0380 0.0385 0.0390 0.0395 0.0400 0.0405

Vel. (ft/sec) -0.086 -0.039 0.016 0.068 0.106 0.122 0.113 0.080 0.031 -0.024 -0.074 -0.109 -0.122 -0.109 -0.074 -0.024 0.032 0.080 0.113 0.122 0.106 0.068 0.016 -0.039 -0.086 -0.115 -0.121 -0.102 -0.061 -0.008 0.046 0.091 0.118 0.120 0.097 0.055 0.001 -0.053 -0.096 -0.119 -0.118

Time (sec) 0.0410 0.0415 0.0420 0.0425 0.0430 0.0435 0.0440 0.0445 0.0450 0.0455 0.0460 0.0465 0.0470 0.0475 0.0480 0.0485 0.0490 0.0495 0.0500 0.0505 0.0510 0.0515 0.0520 0.0525 0.0530 0.0535 0.0540 0.0545 0.0550 0.0555 0.0560 0.0565 0.0570 0.0575 0.0580 0.0585 0.0590 0.0595 0.0600 0.0605 0.0610

Vel.

(ft/sec)
-0.092 -0.048 0.007 0.060 0.101 0.121 0.116 0.087 0.040 -0.015 -0.067 -0.105 -0.122 -0.113 -0.081 -0.033 0.022 0.073 0.109 0.122 0.110 0.076 0.026 -0.030 -0.079 -0.112 -0.122 -0.107 -0.069 -0.018 0.037 0.085 0.115 0.121 0.103 0.063 0.010 -0.045 -0.090 -0.117 -0.120

Time (sec)
0.0615 0.0620 0.0625 0.0630 0.0635 0.0640 0.0645 0.0650 0.0655 0.0660 0.0665 0.0670 0.0675 0.0680 0.0685 0.0690 0.0695 0.0700 0.0705 0.0710 0.0715 0.0720 0.0725 0.0730 0.0735 0.0740 0.0745 0.0750 0.0755 0.0760 0.0765 0.0770 0.0775 0.0780 0.0785 0.0790 0.0795 0.0800 0.0805 0.0810 0.0815

Vel.

(ft/sec)
-0.098 -0.056 -0.003 0.052 0.095 0.119 0.118 0.093 0.049 -0.005 -0.059 -0.100 -0.120 -0.116 -0.088 -0.042 0.013 0.065 0.104 0.121 0.114 0.083 0.035 -0.021 -0.072 -0.108 -0.122 -0.111 -0.077 -0.027 0.028 0.078 0.111 0.122 0.107 0.071 0.020 -0.036 -0.083 -0.114 -0.121

Time (sec) 0.0820 0.0825 0.0830 0.0835 0.0840 0.0845 0.0850 0.0855 0.0860 0.0865 0.0870 0.0875 0.0880 0.0885 0.0890 0.0895 0.0900 0.0905 0.0910 0.0915 0.0920 0.0925 0.0930 0.0935 0.0940 0.0945 0.0950 0.0955 0.0960 0.0965 0.0970 0.0975 0.0980 0.0985 0.0990 0.0995 0.1000

Vel. (ft/sec) -0.103 -0.064 -0.012 0.043 0.089 0.117 0.120 0.099 0.058 0.004 -0.050 -0.094 -0.119 -0.119 -0.095 -0.051 0.003 0.057 0.099 0.120 0.117 0.089 0.044 -0.011 -0.064 -0.103 -0.121 -0.114 -0.084 -0.036 0.019 0.070 0.107 0.122 0.112 0.078 0.029

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Table A.6. Cutter Velocity variation with Lateral Contact Area

Contact Area (in**2) 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0

Cutter Velocity (ft/sec) 70147.222 0.862 0.431 0.287 0.216 0.172 0.144 0.123 0.108 0.096 0.086 0.078 0.072 0.066 0.062 0.057 0.054 0.051 0.048 0.045 0.043 0.041 0.039 0.037 0.036 0.034

Contact Area (in**2) 5.2 5.4 5.6 5.8 6.0 6.2 6.4 6.6 6.8 7.0 7.2 7.4 7.6 7.8 8.0 8.2 8.4 8.6 8.8 9.0 9.2 9.4 9.6 9.8 10.0

Cutter Velocity (ft/sec) 0.033 0.032 0.031 0.030 0.029 0.028 0.027 0.026 0.025 0.025 0.024 0.023 0.023 0.022 0.022 0.021 0.021 0.020 0.020 0.019 0.019 0.018 0.018 0.018 0.017

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Table A.7. Effect of Bit Weight on Cutter Backward Velocity

Bit Weight (Ibf) 5 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Cutter Velocity (ft/sec) 0.755 0.534 0.378 0.308 0.267 0.239 0.218 0.202 0.189 0.178 0.169 0.161 0.154 0.148 0.143 0.138 0.134 0.130 0.126 0.123 0.119 0.117 0.114 0.111 0.109 0.107

Bit Weight (Ibf) 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500

Cutter Velocity (ft/sec) 0.105 0.103 0.101 0.099 0.098 0.096 0.094 0.093 0.092 0.090 0.089 0.088 0.087 0.086 0.084 0.083 0.082 0.081 0.081 0.080 0.079 0.078 0.077 0.076 0.076

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Table A.8. Effect of Stabihzer Position on Cutter Backward Velocity

Stabilizer distance from Bit, ft 1 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60

Cutter Velocity Max. Amplitude (ft/sec) 0.02816 0.07311 0.13759 0.15948 0.16660 0.16937 0.17065 0.17132 0.17169 0.17192 0.17207 0.17217 0.17224 0.17229 0.17232 0.17235 0.17237 0.17238 0.17239 0.17239 0.17240 0.17240 0.17240 0.17240 0.17240 0.17240 0.17240 0.17240 0.17240 0.17240 0.17240

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Table A.9. Effect of Drill Collar Stifhess on Cutter Backward Velocity for given distance of Stabihzer from Bit
Rigidity Modulus (psi) 1.00E+07 1.10E+07 1.15E+07 1.30E+07 1.40E+07 1.50E+07 1.60E+07 1.70E+07 1.80E+07 1.90E+07 2.00E+07 Distance = 3ft 0.1170 0.1140 0.1124 0.1085 0.1061 0.1038 0.1017 0.0997 0.0978 0.0960 0.0943 Distance = 5ft 0.1540 0.1525 0.1517 0.1496 0.1482 0.1468 0.1455 0.1442 0.1429 0.1417 0.1405 Rigidity IViodulus (psi) 2.10E+07 2.20E+07 2.30E+07 2.40E+07 2.50E+07 2.60E+07 2.70E+07 2.80E+07 2.90E+07 3.00E+07 Distance = 3ft 0.0927 0.0912 0.0897 0.0883 0.0870 0.0857 0.0845 0.0833 0.0822 0.0811 Distance = 5ft 0.1393 0.1382 0.1371 0.1360 0.1349 0.1339 0.1329 0.1319 0.1309 0.1300

Table A.IO. Effect of Damping Factor on Cutter Backward Velocity

Damping Factor 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

Cutter Velocity Max. Amplitude (ft/sec) 0.2072 0.2054 0.2002 0.1924 0.1828 0.1724 0.1618 0.1515 0.1417 0.1326 0.1243 0.1167 0.1098 0.1035 0.0978 0.0927

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APPENDIX B MATLAB SOURCE CODE

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B.l %MATLAB program to calculatc the valucs of iuictions S(x), r(x), U(x), F(x). G(x). H(x). P(x), Q(x). R(x) clc;clearan;pl=l;xl=0.0:-0.01:-6.0;xl=xl'; forx-0.0:-0.01:-6.0 sxl=l;sx2=l;sumsx=0;txl=l;tx2=l;sumtx=0;uxl=l;ux2=l;sumux=0; fxl=l;fx2=l;sum6c=0;gxl=l;gx2=l;sumgx=0;hxl=l;hx2=l;sumhx=0; pxl=l;px2=l;sumpx=0;qxl=l;qx2=l;sumqx=0;rxl=l;rx2=l;sumrx=0; forn=l:50 sxl=l;sx2=l;txl=l;tx2=l;uxl=l;ux2=l;fxl=l;fx2=l;gxl=l;gx2=l;hxl=l;hx2=l; pxl=l;px2=l;qxl=l;qx2=l;rxl=l;rx2=l; if n==l % initializing the first terms of diffcrent series to individua! variables sumsxl=x;sumtxl=0.5*x^2;sumuxl=-x'^3/6.0;sumfxl=L0;sumgxl=x; sumhxl=-x^2/2.0;sumpxl=-x'*^2/2.0;sumqxl=1.0;sumrxl=-x; sumsx=sumsx+sumsx 1 ;sumtx=sumtx+sumtx 1 ;sumux=sumux+sumux 1; sumfx=sumfx+sumfxl ;sumgx=sumgx+sumgxl ;sumhx=sumhx+sumhxl; sumpx=sumpx+sumpxl ;sumqx=sumqx+sumqxl ;sumrx=sumrx+sumrxl; else ifn==2 sumqx 1 ^-x'^S/S.0;sumqx=sumqx+sumqx 1; else numqx=(-l)'^(n+l)*x'^(3*n-3);pqx=3*n-3;nqxterms=2*n-4;nqxl=nqxterms/2; foril=l:nqxl qxl=3*il*qxl;qx2=(3*il+l)*qx2; end sumqx 1 =numqx/(pqx*qx 1 );sumqx 1 =sumqx l/qx2;sumqx=sumqx+sumqx 1; end % the following lines evakiates the values of powers of x each tenn of the individual functions numsx^-l^^n-l^^x'^^^^n-^^^numtxK-l^^^n-l^^x^^^^n-l^^numux^^-l^^n^x^^^^n); numfx=(-l)^(n+l)*x^(3*n-3);numgx=(-l)^(n-l)*x^(3*n-2); numhx=(-1 )^n*x^(3 *n-1) ;numpx=(-1 )^n*x'*^(3 *n-1 );numrx=(-1 ^'^n^x^^^ *n-2);

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psx=3*n-2;ptx=3*n-l;pux=3*n;nsxterms=2*n-l;ntxtenns-2*n-2;nuxterms=2*n-2; nf?cterms=2*n-2;ngxterms=2*n-2;nhxterms=2*n-2;npxterms=2*n-2; nrxterms=2*n-2; nsx 1 =(nsxterms-1 )/2 ;ntx 1 =ntxterms/2 ;nux 1 =nuxterms/2; nfx 1 =nfxterms/2 ;ngx 1 =ngxterms/2 ;nhx 1 =nhxterms/2; npx 1 =npxterms/2 ;nrx 1 =nrxterms/2; % the following conditional statements evaluates the integers in each term of Ihe denominators foril=l:nsxl sxl=(3*il-l)*sxl;sx2=3*il*sx2;end foril=l:ntxl txl=3*il*txl;tx2=(3*il+l)*tx2;end foril=l:nuxl uxl=(3*il+l)*uxl;ux2=(3*il+2)*ux2;end foril=l:nfxl fxl=(3*il-l)*fxl;fx2=3*il*fe2;end

foril=l:ngxl gxl=3*il*gxl;gx2=(3*il+l)*gx2;end foril=l:nhxl hxl=(3*il+l)*hxl;hx2=(3*il+2)*hx2;end foril=l:npxl pxl=3*il*pxl;px2=(3*il+2)*px2;end for il=l:nrxl rxl=(3*il-l)*rxl;rx2=(3*il+l)*rx2;end % the following lines sums the individual terms in the series for each function sumsx 1 =numsx/(sx 1 *psx);sumtx 1 =numtx/(tx 1 *ptx);sumux 1 =numux/(2*ux 1 *pux); sumfx 1 =numfx/fx 1; sumgx 1 =numgx/gx 1; sumhx 1 =numhx/(2 *hx 1); sumpx 1 =numpx/(2*px 1 );sumrx 1 =numrx/rx 1; sumsx 1 =sumsx 1 /sx2; sumtx 1=sumtx 1 /tx2; sumux 1=sumux 1 /ux2; sumfx 1 =sumfx 1/fx2; sumgx 1 =sumgx 1/gx2; sumhx 1 =sumhx 1/hx2; sumpx 1 =sumpx 1 /px2; sumrx 1 =sumrx 1 /rx2; % the following three lines represen the fmal values of the each function for given values of x sumsx=sumsx+sumsxl ;sumtx=sumtx+sumtxl ;sumux=sumux+sumuxl; sumfx=sumfx:+sumfx 1 ;sumgx=sumgx+sumgx 1 ;sumhx=sumhx+sunihx 1; sumpx=sumpx+sumpx 1 ;sumrx=sumrx+sumrx 1; end

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end sx(pl)=sumsx;tx(pl)=sumtx;ux(pl)=sumux;fx(pl)=sumfx;gx(pl)=sumgx; hx(p 1 )=sumhx;px(p 1 )=sumpx;qx(p 1 )=sumqx;rx(p 1 )=sumrx; p 1 =p 1+1 end sx=sx';sxo=[xl,sx];tx=tx';txo=[xl,tx];ux=ux';uxo=[xl,ux];fx=fx';fxo=[xLfx];gx=gx': gxo=[x 1 ,gx] ;hx=hx';hxo=[x 1 ,hx] ;px=px';pxo=[x 1 ,px] ;qx=qx';qxo=[x 1 ,qx] ;rx=rx'; rxo=[xl,rx]; % the values of each fimction for given values of x are stored in individual text les showii below saveCsx.txtVsxoV-ascii');save('tx.txtVtxo','-ascii');save('ux.txtVuxoV-ascii'); save(*fx.txtVfxo','-ascii');save('gx.txt','gxo','-ascii');save('hx.txtVhxo','-ascii'); save('px.txt','pxo','-ascii');save('qx.txt','qxo','-ascii');save('rx.txt','rxo','-ascii');

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B.2 %MATLAB program to calculate thc value of xl and x2 and write data to a text fle clc;clearall;pl=l;st=2.7;il=st:-0.0001:0.0;i2=size(il,2); for i=0.0:-0.2:-8.0 % the values of i rcfer to values of xl

[csx,ctx,cux,cfx,cgx,chx,cpx,cqx,crx]=call_det(i); % value of individual functions for dilTerent values of i are evaluated by calling the subroutine sxl(pl)=csx;txl(pl)=ctx;uxl(pl)=cux;6cl(pl)=cfx; % initializing variables gxl(pl)=cgx;hxl(pl)=chx;pxl(pl)=cpx;qxl(pl)=cqx;rxl(pl)=crx; q=i; forxl=st:-0.0001:1.7 [csx,ctx,cux,cfx,cgx,chx,cpx,cqx,crx]=call_det(xl); % value of individual functions for different values of xl are evaluated by calling the subroutine a=[pxl(pl),qxl(pl),rxl(pl);cpx,cqx,crx;sxl(pl)-csx,txl(pl)-ctx,uxl(pl)-cux]; al(q)=det(a);bl(q)=xl; % determinant is evaluated if xl==st gl=abs(al(l));hl=bl(l); % condition to check forthe lowest absolute value of the determinant else if abs(al(q))<=gl gl=abs(al(q));hl=bl(q); end end q=q+l; end cxl(pl)=i;cx2(pl)=hl;c_err(pl)=gl;fprintf('\n%8.5f%8,5f%8.5f,i,hl,gl); pl=pl+l; end cxl=cxl';cx2=cx2';c_err=c__err*;b=[cxl,cx2,c_err];save('ccl.txt','b','-ascii'); % subroutine evaluated below and the individual values of function determined % the subroutine program is similar to the program shown in section B-1 function [sxf,txf,uxf,fxf,gxf,hxf,pxf,qxf,rxf]=call_det(xf)

sxl=l;sx2=l;sumsx=0;txl=l;tx2=l;sumtx=0;uxl=l;ux2=l;sumux=0; fxl=l;fx2=l;sumfx=0;gxl=l;gx2=l;sumgx=0;hxl=l;hx2=l;sumhx=0;

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pxl=l;px2=l;sumpx=0;qxl=l;qx2=l;sumqx=0;rxl=l;rx2=l;sumrx=0; forn=l:20 sxl=l;sx2=l;txl=l;tx2=l;uxl=l;ux2=l; fxl=l;fx2=l;gxl=l;gx2=l;hxl=l;hx2=l;pxl=l;px2=l;qxl=l;qx2=l;ncl=l;rx2=l; ifn==l sumsxl=xf;sumtxl=0.5*xf^2;sumuxl=-xf^3/6.0; sumfxl=1.0;sumgxl=xf;sumhxl=-xf'^2/2.0; sumpxl=-xf^2/2.0;sumqxl=1.0;sumrxl=-xf; sumsx=sumsx+sumsx 1 ;sumtx=sumtx+sumtx 1 ;sumux=sumux+sumux 1; sumfx=sumfx+sumfx 1 ;sumgx=sumgx+sumgx 1 ;sumhx=sumhx+sumhx 1; sumpx=sumpx+sumpx 1 ;sumqx=sumqx+sumqx 1 ;sumrx=sumrx+sumrx 1; eise if n==2 sumqxl=-xf^3/3.0;sumqx=sumqx+sumqxl; else numqx=(-l)'^(n+l)*xf'^(3*n-3);pqx=3*n-3;nqxterms=2*n-4;nqxl=nqxterms/2; for il=l:nqxl qxl=3*il*qxl;qx2=(3*il+l)*qx2;end sumqx 1 =numqx/(pqx*qx 1 );sumqx 1 =sumqx 1 /qx2;sumqx=sumqx+sumqx 1; end numsx=(-l)^(n-l)*xf^(3*n-2);numtx=(-l)^(n-l)*xf^(3*n-l); numux=(-1 ^^n^xf'^^^ *n); numfx=(-l)^(n+l)*xf^(3*n-3);numgx=(-l)^(n-l)*xf^(3*n-2); numhx=(-l)^n*xf^(3*n-l);numpx=(-l)^n*xf^(3*n-l);numrx=(-l)^n*xf^(3*n-2); psx=3*n-2;ptx=3*n-l;pux=3*n; nsxterms=2*n-l;ntxterms=2*n-2;nuxterms=2*n-2; nfxterms=2*n-2;ngxterms=2*n-2;nlixterms=2*n-2; npxterms=2*n-2; nrxterms=2 *n-2; nsx 1 =(nsxterms-1 )/2 ;ntx 1 =ntxterms/2;nux 1 =nuxterms/2; nfx 1 =nfxterms/2 ;ngx 1 =ngxterms/2 ;nhx 1 =nhxterms/2; npx 1 =npxterms/2;nrx 1 =nrxterms/2; foril=l:nsxl sxl=(3*il-l)*sxl;sx2=3*il*sx2;end foril=l:ntxl txl=3*il*txl;tx2=(3*il+l)*tx2;end foril=l:nuxl uxl=(3*il+l)*uxl;ux2=(3*il+2)*ux2;end foril=l:nfxl fxl=(3*il-l)*fxl;fx2=3*il*fx2;end

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foril=l ngxl gxl=3*il*gxl;gx2=(3*il+l)*gx2;end foril=l:nhxlhxl=(3*il+l)*hxl;hx2=(3*il+2)*hx2;end foril=l:npxl pxl=3*il*pxl;px2=(3*il+2)*px2;end foril=l:nrxlrxl=(3*il-l)*rxl;rx2=(3*il+l)*rx2;end sumsx 1 =numsx/(sx 1 *psx);sumtx 1 =numtx/(tx 1 *ptx);sumux 1 =numux/(2*ux 1 *pux); sumfx 1 =numfx/fxl ;sumgx 1 =numgx/gx 1 ;sumhx 1 =numhx/(2*hx 1); sumpx 1 =numpx/(2 *px 1); sumrx 1 =numrx/rx 1; sumsx 1 =sumsx 1 /sx2; sumtx 1=sumtx 1 /tx2; sumux 1 =sumux 1 /ux2; sumfx 1 =sumfx 1/fx2; sumgx 1=sumgx 1/gx2; sumhx 1 =sumhx 1/hx2; sumpx 1 =sumpx 1 /px2; sumrx 1=sumrx 1 /rx2; sumsx=sumsx+sumsx 1 ;sumtx=sumtx+sumtx 1 ;sumux=sumux+sumux 1; sumfx=sumfx:+sumfx 1 ;sumgx=sumgx+sumgx 1 ;sumhx=sumhx+sumhx 1; sumpx=sumpx+sumpx 1 ;sumrx=sumrx+sumrx 1; end end sxf=sumsx;txf=sumtx;uxf=sumux; fxf=sumfx;gxf^sumgx;hxf=sumhx; pxf=sumpx;qxf=sumqx;rxf=sumrx; retum

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B.3 %MA'ri.AB program for calculating the tangcncy point x3 for frst order critical buckiing clc; clear all pl=l;st=L94; [csx,ctx,cux,cfx,cgx,chx,cpx,cqx,crx]=call_det(-6.0); %function values evaluated by calhng subroutine. Subroutine program hsted in section B-2. sxl=csx;txl=ctx;uxl=cux;fxl=cfx; gxl=cgx;hxl=chx;pxl=cpx;qxl=cqx;rxl=crx; [csx,ctx,cux,cfx,cgx,chx,cpx,cqx,crx]=call_det(1.94); sx2=csx;tx2=ctx;ux2=cux;fx2=cfx; gx2=cgx;hx2=chx;px2=cpx;qx2=cqx;rx2=crx; for i=st:-0.0001:0.0 % this if statement evaluates the determinant and checks for the lowest absolute value of the detemiinant [csx,ctx,cux,cfx,cgx,chx,cpx,cqx,crx]=call_det(i); a=[cfx,cgx,chx;px 1 ,qx 1 ,rx 1 ;px2,qx2,rx2]; al (p 1 )=det(a);b 1 (p 1 )=i; if i==st gl=abs(al(l));hl=bl(l); else if abs(al(pl))<-gl gl=abs(al(pl));hl=bl(pl); end end pi=pi+i; end fjprintf('\nThe Value of X3 =%8.5f ,hl); % the distance between the neutral point and taiigency point is determined.

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R4 %MATl.AB program to calculate thc value of x2 when the second bucklc contacts the borehole wall clc;clear all wt=input('Weight per unit length of Drill-Collars (Ib/ft):'); e=input('Elastic Modulus (lbf/in**2):'); od=input('Drill Colkir O.D (in.):'); id=input('Drill-Collar I.D (in.):'); hdia=input('Dia. of Hole (in.):'); mi=pi*(odM-idM)/(12M*64.0);m=(e*144*mi/wt)^0.3333; % calculates moment of inertia of drill collar and lcngth of one dimcnsionless unit of drill collar r=(hdia-od)/(2.0* 12);x2=4.1:0.001:4.5;x2=x2'; [csxl,ctxl,cuxl,cfxl,cgxl,chxl,cpxl,cqxl,crxl]=call_det(-6.0); % subroutine evaluated for xl =-6.0 and values of diflerent functions determined. Subroutine listed in section B-2 % the ibllowing for statements are evaluated in loop until ibr a particular value of i2, ihe determinant is equal to the lowest possible absolute value. This value of i2 equals to the value of x2 when the second buckle contacts the bore hole w'all. for i2=l:size(x2,l) q=l;dl=[];el=[];st=3.0; [Csx2,ctx2,cux2,cfx2,cgx2,chx2,cpx2,cqx2,crx2]=call_det(x2(i2)); forx3=st:0.0001:3.2 [csx3,ctx3,cux3,cfx3,cgx3,chx3,cpx3,cqx3,crx3]=call_det(x3); a=[cpxl,cqxl,crxl,0.0,0.0,0.0,0.0;cf c3,cgx3,chx3,0.0,0.0,0.0,0.0;... (csx3-csxl),(ctx3-ctxl),(cux3-cuxl),0.0,0.0,0.0,r/m;... 0.0,0.0,0.0,cpx2,cqx2,crx2,0.0;... 0.0,0.0,0.0,cfx3,cgx3,chx3,0.0;0.0,0.0,0.0,(csx3-csx2),(ctx3-ctx2),(cux3cux2),r/m; cpx3,cqx3,crx3,-cpx3,-cqx3,-crx3,0.0]; dl(q)=det(a);el(q)=x3; if abs(dl(q))<=0.01 gl=abs(dl(q));hl=el(q);i2=size(x2,l)+l; break; end q=q+l; end end

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B.5 /oMA IT..AB program to calculate the equation coefficients, values of x2, x3 and thc force coeffcient f clc; clear all wt=input('Weight per unit length of Drill-Collars (Ib/ft):'); e=input('EIastic Modulus (Ibf/in**2):'); od=input('Drill Colkir O.D (in.):'); id=input('DriII-Collar I.D (in.):'); hdia=input('Dia. of Hole (in.):'); mi=pi*(od^4-idM)/(12M*64.0); m=(e* 144*^1/^^)^^0.3333; r=(hdia-od)/(2.0*12);x2=[1.94,2.0,2.3,2.6,3.2,3.5,3.753,4.0,4.1,4.218]'; pl=l;xl=-6.0;st=0.0;il=size(x2,l); [csxl,ctxl,cuxl,cf!l,cgxl,chxl,cpxl,cqxl,crxl]=caII_det(-6.0); %function value at xl==6.0 evaluated by calling subroutine. sx 1 =csx 1 ;tx 1 =ctx 1 ;ux 1 =cux 1 ;fx 1 =cfx 1; gx 1 =cgx 1 ;hx 1 =chx 1 ;px 1 =cpx 1 ;qx 1 =cqx 1 ;rx 1 =crx 1; % the following for statements are evaluated in loop until for a particular value of i, the determinant is equal to the lowest possible absokite value. fori=l:il [csx(i),ctx(i),cux(i),cfx(i),cgx(i),chx(i),cpx(i),cqx(i),crx(i)]=call_det(x2(i)); q=l; forx3=st:0.0001:st+l [Csx3,ctx3,cux3,cfx3,cgx3,chx3,cpx3,cqx3,crx3]=call_det(x3); a=[pxl,qxl,rxl,0.0,0.0,0.0,0.0;cfx3,cgx3,chx3,0.0,0.0,0.0,0.0;... (csx3-sxl),(ctx3-txl),(cux3-uxl),0.0,0.0,0.0,r/m;... O.0,O.O,0.O,cpx(i),cqx(i),crx(i),0.O;.O,0.0,O.0,cfx3,cgx3,chx3,0.O;... 0.0,0.0,0.0,(csx3-csx(i)),(ctx3-ctx(i)),(cux3-cux(i)),r/m;... cpx3,cqx3,crx3,-cpx3,-cqx3,-crx3,0.0]; dl(q)=det(a);el(q)=x3;

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ifabs(dl(q))<=0.01 gl=abs(dl(q));hl=el(q); break; end q=q+i; end cx2(pl)=x2(i);cx3(pl)=hl;c_err(pl)=gl;st=cx3(pl); % the values of the coefficients al. bl, cl and a2. b2, c2 from the simultaneous equations are determined Cl(i)=l/((csx3-sxl)*(qxl*chx3-cgx3*rxl)/(pxl*cgx3-cfx3*qxl)+(cux3-uxl)+... (Ctx3-txl)*(rxl*cfx3-pxl*chx3)/(pxl*cgx3-cfx3*qxl)); al(i)=(qxl*chx3-cgx3*rxl)*cl(i)/(pxl*cgx3-cfx3*qxl); bl(i)=(rxl*cfx3-pxl*chx3)*cl(i)/(pxl*cgx3-cfx3*qxl); C2(i)=l/((csx3-csx(i))*(cqx(i)*chx3-cgx3*crx(i))/(cpx(i)*cgx3-cfx3*cqx(i))+... (cux3-cux(i))+(ctx3-ctx(i))*(crx(i)*cfx3-chx3*cpx(i))/(cpx(i)*cgx3-cfx3*cqx(i))): a2(i)=(cqx(i)*chx3-cgx3*crx(i))*c2(i)/(cpx(i)*cgx3-cfx3*cqx(i)); b2(i)=(crx(i)*cfx3-chx3*cpx(i))*c2(i)/(cpx(i)*cgx3-cfx3*cqx(i)); f(i)=c2(i)*m/r-cl(i)*m/r; % the force coefllcient is determined ^rintf('\n%8.5f%8.5f%8.5f,x2(i),hl,gl); ^rintf('\n%8.5f%8.5f%8.5f%8.5f%8.5f%8.5f %8.5f,x2(i),al(i),bl(i),cl(i),a2(i),b2(i),c2(i)); pl=pl+l; end cx2=cx2';cx3=cx3';c_err=c_err';f=f; al=al';bl=br;cl=cr;a2=a2';b2=b2';c2=c2'; tl=[cx2,cx3,c_err]; t2=[al,bl,cl,a2,b2,c2];t3=[x2,f]; % the values of x2 and x3, the coeflcients (al, bl, cl, a2, b2, c2) and the brce cocfflcients data variation with x2 are stored in respective fllcs below. save('cc2_tl.txt','tl','-ascii');save('cc2_t2.txt','t2','-ascii');save('f_value.txt','t3','-ascii');

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R6 AMAITAB program for calculating the x-y values for dctennining shapc of buckled dnlling string and bending moment coefficients for frst and higher buckling orders clc; clear all wt=input('Weight per unit length of Drill-CoUars (Ib/ft):'); e=input('EIastic Modulus (Ibf/in**2):'); od=input('Drill CoIIai- O.D (in.):'); id=input('DriII-Collar I.D (in.):'); hdia=input('Dia. of Hole (in.):'); mi=pi*(odM-idM)/(12M*64.0);m=(e*144*mi/wt)^0.3333; r=(hdia-od)/(2.0*12);x2=[1.94,3.753,4.219]'; [csxl,ctxl,cuxl,cfxl,cgxl,chxl,cpxl,cqxl,crxl]=caIl_det(-6.0); % function values at xl==-6.0 determined by calling subroutine for i2=l:3 q=l;x4=-x2(i2)-6.0;dl=[];el=[]; x=x2(i2):-0.1:x4;x=x'; il=size(x,l); [Csx2,ctx2,cux2,cfx2,cgx2,chx2,cpx2,cqx2,crx2]=call_det(x2(i2)); %llinction values evaluated at different values of x2, i.e.1.94, 3.753, 4.219, by calling subroutine if i2==l st=0.0; elseif i2==2 st=2.0; elseif i2==3 st=3.0; end for x3=st:0.0001:x2(i2) % valucs of x3 detcrmined for given value of xl and x2 > [Csx3,ctx3,cux3,cfx3,cgx3,chx3,cpx3,cqx3,crx3]=call_det(x3); a=[cpxl,cqxl,crxl,0.0,0.0,0.0,0.0;cfic3,cgx3,chx3,0.0,0.0,0.0,0.0;... (csx3-csxl),(ctx3-ctxl),(cux3-cuxl),0.0,0.0,0.0,r/m;... 0.0,0.0,0.0,cpx2,cqx2,crx2,0.0;0.0,0.0,0.0,cf!3,cgx3,chx3,0.0;... 0.0,0.0,0.0,(csx3-csx2),(ctx3-ctx2),(cux3-cux2),r/m;... Cpx3,cqx3,crx3,-cpx3,-cqx3,-crx3,0.0]; dl(q)=det(a);el(q)=x3; if abs(dl(q))<=0.01 gl(i2)=abs(dl(q));hl(i2)=el(q); break; end q=q+l; end

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Cx2(i2)=x2(i2);cx3(i2)=hl(i2);c_err(i2)=gl(i2); /i the values of coefficicnts for upper and lower region (al, bl, cl, a2, b2, c2) are determined Cl=l/((csx3-csxl)*(cqxl*chx3-cgx3*crxl)/(cpxl*cgx3-cfx3*cqxl)+(cux3-cuxl)+... (ctx3-ctxl)*(crxl*cfx3-cpxl*chx3)/(cpxl*cgx3-cfx3*cqxl)); al=(cqxl*chx3-cgx3*crxl)*cl/(cpxl*cgx3-cfx3*cqxl); bl=(crxl*cfx3-cpxl*chx3)*cl/(cpxl*cgx3-cfx3*cqxl); C2=l/((csx3-csx2)*(cqx2*chx3-cgx3*crx2)/(cpx2*cgx3-cfx3*cqx2)+... (Cux3-cux2)+(ctx3-ctx2)*(crx2*cfx3-chx3*cpx2)/(cpx2*cgx3-cfx3*cqx2)); a2=(cqx2*chx3-cgx3*crx2)*c2/(cpx2*cgx3-cfx3*cqx2); b2=(crx2*cfx3-chx3*cpx2)*c2/(cpx2*cgx3-cfx3*cqx2); fprintf('\n%8.5f %8.5f %8.5f %8.5f %8.5f %8.5f %8.5f %8.5f,x2(i2),hl(i2),al,bl,cl,a2,b2,c2); fori=l:il xl(i)=x2(i2)-x(i); [csx(i),ctx(i),cux(i),cfx(i),cgx(i),chx(i),cpx(i),cqx(i),crx(i)]=call_det(x(i)); if x(i)<cx3(i2) % value of y evaluated for portion of string above tangency point y(i)=al*(csx(i)-csxl)+bl*(ctx(i)-ctxl)+cl*(cux(i)-cuxl); bm(i)=(al*(cpx(i)-cpxl)+bl*(cqx(i)-cqxl)+cl*(crx(i)-crxl)); % bending momcnt coeffcient ten i evaluated else % value of y evaluated for portion of string below tangency point y(i)=a2*(csx(i)-csx2)+b2*(ctx(i)-ctx2)+c2*(cux(i)-cux2); bm(i)=(a2*(cpx(i)-cpx2)+b2*(cqx(i)-cqx2)+c2*(crx(i)-crx2)); % bending moment coeff cient term evaluated end fprintf('\n%8.5f%8.5f%8.5f,xl(i),y(i),bm(i)); end if i2==l xl=xr;y=y';bm=bm'; end if i 2 = l tl=[xl,y];bml=[xl,bm]; elseif i2==2 t2=[xl,y];bm2=[xl,bm];

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elseif i2==3 t3=[x 1 ,y] ;bm3=[x 1 ,bm] ;end end % text fies for x-y values at first buckling order, second buckling order and when second buckle contacts bore-hole wall are generated save('xyvall.txt','tr,'-ascii');save('xyval2.txt','t2','-ascii');save('xyval3.txt','t3','-ascii'); % corresponding bending moments data fles are generated below save('bmvall.txt','bml','-ascii');save('bmval2.txt','bm2','-ascii'); save('bmval3.txt','bm3','-ascii');

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