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

这笔赠款用于建立科学和技术基础，用于测量聚晶金刚石岩石切割刀片与岩石之间的接触区附近的温度和力，并为其预测建立模型。通过扩散连接两个多晶金刚石板，即带有通过微制造技术沉积的传感器的底板和与岩石接触的盖子，将微型薄膜热机械传感器嵌入到距离接触区仅几百微米的插入物中，从而实现传感。要实现这一任务，就必须研究多晶金刚石和传感器之间的粘接过程和相互扩散的机理。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，将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开发的模型的性能进行全面的实验验证。如果成功，这项研究的结果将带来新的工具，以提高石油和天然气的勘探和开采能力。独一无二的嵌入式传感技术的问世，可能会使人们对岩石切割力学的基本理解和创新的监测/控制技术产生巨大的飞跃。传感器能够从镶嵌-岩石界面附近提供过程变量的实时测量，这将允许在凿岩/切割操作中控制最佳渗透率。所开发的方法还将作为一个平台，进一步将嵌入式微型传感器技术移植/溢出到先进制造的各个领域。

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.