CN111761059A - Process for preparing PDC drill bit through 3D printing - Google Patents
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Abstract
The invention discloses a process for preparing a PDC drill bit by 3D printing, which comprises the following steps: step S1, modeling; step S2, batching; step S3, raw material processing; and step S4, printing and preparing the PDC drill bit. The PDC drill bit manufactured by adopting the additive technology through laser printing has the characteristics of short production period and low cost, and the printed PDC drill bit has high strength, good stability, excellent erosion resistance and wide application market.
Description
Technical Field
The invention relates to the technical field of petroleum development drilling devices, in particular to a process for preparing a PDC drill bit through 3D printing.
Background
In petroleum drilling, the PDC drill bit has wide application due to the advantages of high mechanical drilling speed, long drill bit footage service life and the like. With the development of the drilling process and the increasing complexity of the drilling working condition, the higher requirement is put forward on the rotating speed of the PDC drill bit on the premise of ensuring the safety of the bit scraper. At present, two methods are mainly used for manufacturing the PDC drill bit body, one method is formed by combining and sintering powder metallurgy and a steel body through a die, the other method is formed by forging and turning and milling round steel, and then cutting teeth are embedded on the drill bit body. Therefore, a manufacturing process of the PDC drill bit, which has the advantages of high machining precision, short production process period, easiness in operation and low cost, is needed.
Chinese patent CN104353833A discloses a 3D printing manufacturing method of PDC bit body, comprising the following steps: establishing a three-dimensional model of the PDC bit body; carrying out two-dimensional processing on the three-dimensional model; generating a corresponding laser scanning path according to the formed two-dimensional graph; uniformly paving a plurality of layers of metal material powder on a machining platform of additive manufacturing equipment; scanning the metal material powder on the processing platform according to the laser scanning path, and separating the PDC bit body from the surface of the processing platform in a linear cutting mode; carrying out various processes of spray welding of the wear-resistant layer on the bit body by taking the technical requirements of the designed PDC bit body as the standard; and finally forming and manufacturing the PDC drill bit body after flaw detection and cleaning.
Disclosure of Invention
Aiming at the problems, the invention provides a process for preparing a PDC drill bit through 3D printing.
The technical scheme adopted by the invention for solving the problems is as follows: a process for preparing a PDC drill bit through 3D printing comprises the following steps:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 80-100 mu m;
step S2, batching: mixing tungsten carbide powder, cobalt powder, nickel powder and the pretreated carbon powder, and then conveying the mixture to a ball mill for grinding for 30-50 minutes to obtain a premixed raw material;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to obtain a raw material liquid, and then carrying out spray drying on the raw material liquid to obtain raw material particles;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
The tungsten carbide powder, the bonding material cobalt powder and the pretreatment carbon powder are subjected to ball milling and mixing, and then raw material melting treatment is performed, so that the fusibility of raw material particles can be improved, other raw materials are wrapped on the surface of the tungsten carbide, the decarbonization of the tungsten carbide in the printing process is reduced, and the mechanical property of the PDC drill bit is improved.
Further, in step S2, the premix raw materials include, by weight: 100 parts of tungsten carbide powder, 3-6.5 parts of cobalt powder, 1.2-2.5 parts of nickel powder and 0.5-1.8 parts of pretreatment carbon powder.
Furthermore, the premixed raw materials comprise the following components in parts by weight: 100 parts of tungsten carbide powder, 4.8 parts of cobalt powder, 1.8 parts of nickel powder and 1.2 parts of pretreatment carbon powder.
Further, in step S2, the tungsten carbide powder includes tungsten carbide powder having a particle size of 1.0 μm to 1.5 μm, tungsten carbide powder having a particle size of 0.2 μm to 0.6 μm, and tungsten carbide powder having a particle size of 5 μm to 10 μm.
Further, the tungsten carbide powder comprises 30 to 50 parts of tungsten carbide powder with the grain diameter of 1.0 to 1.5 mu m, 30 to 40 parts of tungsten carbide powder with the grain diameter of 0.2 to 0.6 mu m and 10 to 40 parts of tungsten carbide powder with the grain diameter of 5 to 10 mu m.
The tungsten carbide powder with different particle sizes is selected to reduce the porosity among particles, enhance the flowability of the powder, improve the compactness of the PDC drill bit obtained by printing, and further improve the strength and the erosion resistance of the PDC drill bit.
Further, in step S2, the particle size of the cobalt powder is between 2.0 μm and 6.0 μm.
Further, in step S2, the preparation method of the pre-treated carbon powder includes: mixing the carbon powder with stearic acid powder and a silane coupling agent according to a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain the pretreated carbon powder with the particle size.
The carbon powder, stearic acid powder and coupling agent are subjected to ball milling and premixing, so that the problems of poor bonding performance and poor flowability of the tungsten carbide powder during 3D printing can be effectively solved.
Further, in step S3, the spray drying process specifically includes: the raw material liquid is put into an atomizer for atomization, is carried into a high-temperature reaction furnace through carrier gas, solvent evaporation and solute precipitation are completed instantly, and raw material particles with the particle size of 20-50 mu m are screened.
The invention also aims to provide the PDC drill bit which is prepared according to the D printing preparation process.
The invention has the advantages that:
(1) according to the method, tungsten carbide powder with different particle sizes is selected according to different raw material proportions, so that the porosity among particles can be reduced, the flowability of the powder is enhanced, the compact type of the PDC drill bit obtained by printing is improved, and the strength and the erosion resistance of the PDC drill bit are improved;
(2) according to the invention, the carbon powder, stearic acid powder and coupling agent are subjected to ball milling and premixing, so that the problems of poor bonding performance and poor fluidity of tungsten carbide powder during 3D printing can be effectively solved;
(3) the PDC drill bit manufactured by adopting the additive technology through laser printing has the characteristics of short production period and low cost, and the printed PDC drill bit has high strength, good stability, excellent erosion resistance and wide application market.
Detailed Description
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
FIG. 1 is a comparison of the performance of PDC bits made by 3D printing according to the present invention versus conventional processes.
Example 1
A PDC drill bit is prepared by the following 3D printing process:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 90 mu m;
step S2, batching:
step S21, preparation of pretreated carbon powder: mixing the carbon powder with stearic acid powder and a silane coupling agent in a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain pretreated carbon powder with a particle size;
step S22, mixing 100 parts of tungsten carbide powder, 4.8 parts of cobalt powder, 1.8 parts of nickel powder and 1.2 parts of pretreatment carbon powder, and then sending the mixture to a ball mill for grinding for 40 minutes to obtain a premixed raw material, wherein the tungsten carbide powder comprises 40 parts of tungsten carbide powder with the particle size of 1.0-1.5 microns, 35 parts of tungsten carbide powder with the particle size of 0.2-0.6 microns and 25 parts of tungsten carbide powder with the particle size of 5-10 microns, and the particle size of the cobalt powder is 2.0-6.0 microns;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to form a raw material liquid, then putting the raw material liquid into an atomizer for atomization, carrying the atomized raw material liquid into a high-temperature reaction furnace through carrier gas, instantly completing solvent evaporation and solute precipitation, and screening raw material particles with the particle size of 20-50 microns;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
Example 2
A PDC drill bit is prepared by the following 3D printing process:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 80 mu m;
step S2, batching:
step S21, preparation of pretreated carbon powder: mixing the carbon powder with stearic acid powder and a silane coupling agent in a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain pretreated carbon powder with a particle size;
step S22, mixing 100 parts of tungsten carbide powder, 3 parts of cobalt powder, 2.5 parts of nickel powder and 1.0 part of pretreated carbon powder, and then sending the mixture to a ball mill for grinding for 30 minutes to obtain a premixed raw material, wherein the tungsten carbide powder comprises 30 parts of tungsten carbide powder with the particle size of 1.0-1.5 microns, 30 parts of tungsten carbide powder with the particle size of 0.2-0.6 microns and 40 parts of tungsten carbide powder with the particle size of 5-10 microns, and the particle size of the cobalt powder is 2.0-6.0 microns;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to form a raw material liquid, then putting the raw material liquid into an atomizer for atomization, carrying the atomized raw material liquid into a high-temperature reaction furnace through carrier gas, instantly completing solvent evaporation and solute precipitation, and screening raw material particles with the particle size of 20-50 microns;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
Example 3
A PDC drill bit is prepared by the following 3D printing process:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 100 mu m;
step S2, batching:
step S21, preparation of pretreated carbon powder: mixing the carbon powder with stearic acid powder and a silane coupling agent in a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain pretreated carbon powder with a particle size;
step S22, mixing 100 parts of tungsten carbide powder, 6.5 parts of cobalt powder, 1.5 parts of nickel powder and 1.8 parts of pretreatment carbon powder, and then sending the mixture to a ball mill for grinding for 30 to 50 minutes to obtain a premixed raw material, wherein the tungsten carbide powder comprises 50 parts of tungsten carbide powder with the particle size of 1.0 to 1.5 mu m, 40 parts of tungsten carbide powder with the particle size of 0.2 to 0.6 mu m and 10 parts of tungsten carbide powder with the particle size of 5 to 10 mu m, and the particle size of the cobalt powder is 2.0 to 6.0 mu m;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to form a raw material liquid, then putting the raw material liquid into an atomizer for atomization, carrying the atomized raw material liquid into a high-temperature reaction furnace through carrier gas, instantly completing solvent evaporation and solute precipitation, and screening raw material particles with the particle size of 20-50 microns;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
Example 4
A PDC drill bit is prepared by the following 3D printing process:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 80-100 mu m;
step S2, batching:
step S21, preparation of pretreated carbon powder: mixing the carbon powder with stearic acid powder and a silane coupling agent in a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain pretreated carbon powder with a particle size;
step S22, mixing 100 parts of tungsten carbide powder, 4 parts of cobalt powder, 2.0 parts of nickel powder and 0.5 part of pretreated carbon powder, and then sending the mixture to a ball mill for grinding for 30 to 50 minutes to obtain a premixed raw material, wherein the tungsten carbide powder comprises 50 parts of tungsten carbide powder with the particle size of 1.0 to 1.5 mu m, 40 parts of tungsten carbide powder with the particle size of 0.2 to 0.6 mu m and 10 parts of tungsten carbide powder with the particle size of 5 to 10 mu m, and the particle size of the cobalt powder is between 2.0 to 6.0 mu m;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to form a raw material liquid, then putting the raw material liquid into an atomizer for atomization, carrying the atomized raw material liquid into a high-temperature reaction furnace through carrier gas, instantly completing solvent evaporation and solute precipitation, and screening raw material particles with the particle size of 20-50 microns;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
Comparative example 1
A PDC drill bit is prepared by the following 3D printing process:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 90 mu m;
step S2, batching: 100 parts of tungsten carbide powder, 4.8 parts of cobalt powder, 1.8 parts of nickel powder and 1.2 parts of carbon powder are mixed and then sent to a ball mill for grinding for 40 minutes to obtain a premixed raw material, wherein the tungsten carbide powder comprises 40 parts of tungsten carbide powder with the particle size of 1.0-1.5 mu m, 35 parts of tungsten carbide powder with the particle size of 0.2-0.6 mu m and 25 parts of tungsten carbide powder with the particle size of 5-10 mu m, and the particle size of the cobalt powder is 2.0-6.0 mu m;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to form a raw material liquid, then putting the raw material liquid into an atomizer for atomization, carrying the atomized raw material liquid into a high-temperature reaction furnace through carrier gas, instantly completing solvent evaporation and solute precipitation, and screening raw material particles with the particle size of 20-50 microns;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
Comparative example 2
A PDC drill bit is prepared by the following 3D printing process:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 90 mu m;
step S2, batching:
step S21, preparation of pretreated carbon powder: mixing the carbon powder with stearic acid powder and a silane coupling agent in a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain pretreated carbon powder with a particle size;
step S22, mixing 100 parts of tungsten carbide powder, 4.8 parts of cobalt powder, 1.8 parts of nickel powder and 1.2 parts of pretreatment carbon powder, and then sending the mixture to a ball mill for grinding for 40 minutes to obtain a premixed raw material, wherein the tungsten carbide powder comprises 40 parts of tungsten carbide powder with the particle size of 1.0-1.5 microns, 35 parts of tungsten carbide powder with the particle size of 0.2-0.6 microns and 25 parts of tungsten carbide powder with the particle size of 5-10 microns, and the particle size of the cobalt powder is 2.0-6.0 microns;
step S3, printing and preparing the PDC bit:
step S31, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S32, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
Examples of the experiments
To further illustrate the technological advancement of the present invention, experiments are now taken to further illustrate it.
The experimental method comprises the following steps: the technological analysis of the PDC drill bits printed and prepared in the embodiments 1-43D of the invention is shown in Table 1, and the performance analysis is shown in FIG. 1.
TABLE 1 comparison of 3D-printed PDC bits with conventional processes
| Conventional process | 3D printing process | Percent reduction | |
| Manufacturing cycle (sky) | 14 | 5 | 64％ |
| Price of carcass (6 inch) (U.S. dollar) | 4400 | 2500 | 43％ |
| Price of carcass (8 inch) (U.S. dollar) | 6400 | 300 | 48％ |
| Price of carcass (12 inch) (U.S. dollar) | 12000 | 6000 | 50％ |
The experimental result shows that the manufacturing period of the PDC drill bit prepared by the invention is shortened by 64% compared with the traditional process, the price of a PDC matrix is reduced by more than 40%, the strength of the PDC drill bit is enhanced by 50%, and the erosion resistance is increased by 400%.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes will occur to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. The process for preparing the PDC drill bit through 3D printing is characterized by comprising the following steps of:
step S1, modeling: establishing a three-dimensional model of the PDC drill bit, and decomposing the three-dimensional model of the PDC drill bit into a series of two-dimensional slice models with the thickness of 80-100 mu m;
step S2, batching: mixing tungsten carbide powder, cobalt powder, nickel powder and the pretreated carbon powder, and then conveying the mixture to a ball mill for grinding for 30-50 minutes to obtain a premixed raw material;
step S3, raw material processing: melting the premixed raw material obtained in the step B in a high-temperature furnace to obtain a raw material liquid, and then carrying out spray drying on the raw material liquid to obtain raw material particles;
step S4, printing and preparing the PDC bit:
step S41, feeding the raw material particles obtained in the step S3 into a printing platform of a 3D printer, rolling and layering, scanning the raw material particles on the printing platform by using high-energy laser, and solidifying the raw material particles on the surface of the printing platform after melting;
and step S42, laying a second layer of raw material particles on the surface of the consolidated raw material particles, continuing to scan the raw material particles on the printing platform by using high-energy laser to complete the consolidation of the second layer of raw material particles, and stacking and forming layer by layer to obtain the PDC drill bit.
2. The process for 3D printing and preparing a PDC drill bit according to claim 1, wherein in the step S2, the premixed raw materials comprise, in parts by weight: 100 parts of tungsten carbide powder, 3-6.5 parts of cobalt powder, 1.2-2.5 parts of nickel powder and 0.5-1.8 parts of pretreatment carbon powder.
3. The process for preparing the PDC drill bit through 3D printing according to claim 2, wherein the premixed raw materials comprise, by weight: 100 parts of tungsten carbide powder, 4.8 parts of cobalt powder, 1.8 parts of nickel powder and 1.2 parts of pretreatment carbon powder.
4. The process for preparing a PDC bit through 3D printing as claimed in claim 1, wherein the tungsten carbide powder includes tungsten carbide powder having a particle size of 1.0-1.5 μm, tungsten carbide powder having a particle size of 0.2-0.6 μm, and tungsten carbide powder having a particle size of 5-10 μm in step S2.
5. The process for preparing the PDC bit through 3D printing according to claim 4, wherein the tungsten carbide powder comprises 30 to 50 parts of tungsten carbide powder with the grain size of 1.0 to 1.5 microns, 30 to 40 parts of tungsten carbide powder with the grain size of 0.2 to 0.6 microns and 10 to 40 parts of tungsten carbide powder with the grain size of 5 to 10 microns.
6. The process for preparing the PDC bit through 3D printing according to claim 1, wherein in the step S2, the particle size of the cobalt powder is between 2.0 and 6.0 μm.
7. The process for preparing PDC drill bit through 3D printing according to claim 1, wherein the preparation method of the pre-processed carbon powder in the step S2 includes: mixing the carbon powder with stearic acid powder and a silane coupling agent according to a weight ratio of 100:8:2, and performing ball milling for 2 hours at a rotation speed of 450 revolutions per minute to obtain the pretreated carbon powder with the particle size.
8. The process for preparing PDC drill bit through 3D printing according to claim 1, wherein in the step S3, the spray drying process comprises the following specific steps: the raw material liquid is put into an atomizer for atomization, is carried into a high-temperature reaction furnace through carrier gas, solvent evaporation and solute precipitation are completed instantly, and raw material particles with the particle size of 20-50 mu m are screened.
9. A PDC drill bit, characterized in that it is prepared according to the 3D printing preparation process of any one of claims 1-8.
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