Three-dimensional numerical simulation of the straight shale cutting process of single polycrystalline diamond cutter

The finite element method offers a cost-effective way to test the performance of polycrystalline diamond compact (PDC) cutters, which is much cheaper than lab experiments. However, the finite element simulation often fails to output accurate results, owing to improper model selection and parameter setting. To solve the problem, this paper carries out a three-dimensional (3D) simulation of the straight shale cutting process of a single PDC cutter on finite element software Abaqus. The model size, material model, damage, and failure criterion were determined through triaxial tests on the shale. The adaptive meshing method and mass scaling were adopted to improve the calculation stability and reduce the simulation cost. The simulation reveals the residual stress field in the shale, the reaction force to the PDC cutter, and the relationship between the three components of the reaction force. Based on the simulation results, the authors explored the effects of back rake angle, side rake angle, cutting depth, cutter diameter, and confining pressure on the cutting force and vertical force. Our results were found consistent with those of the previous theoretical analyses and experiments. The numerical simulation of cutter-rock interaction provides an effective way for the design of new PDC cutters.