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

这项拨款用于建立科学和技术基础，以测量聚晶金刚石岩石切削齿与岩石之间接触区域附近的温度和力，并为其预测制定模型。通过扩散键合，将微尺度薄膜热机械传感器嵌入到距离接触区仅几百微米的镶块中，即通过微加工技术沉积传感器的基片和与岩石接触的覆盖层。为了实现这一任务，需要对多晶金刚石与传感器之间的键合过程和相互扩散的力学进行研究。还将开发静态和动态传感器校准方法。分析模型的发展将脱离经典的剪切面假设，基于弯曲的宏观裂纹扩展路径和统计方法来描述岩石的性质。数值有限元模型将采用基于微裂纹的连续损伤模型。还计划对嵌入式传感器和所开发模型的性能进行全面的实验验证。如果成功，这项研究的结果将导致新的工具，更有效的石油和天然气勘探和开采能力。独特的嵌入式传感技术的可用性可能会导致对岩石切割力学的基本理解和创新的监测/控制技术的巨大飞跃。传感器能够实时测量插入-岩石界面附近的过程变量，从而可以在岩石钻井/切割作业中控制最佳的钻速。开发的方法还将作为嵌入式微传感器技术进一步迁移/溢出到先进制造的各个领域的平台。

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