Determination of optimal PDC cutters geometry for multi-response optimization using the Taguchi method

Nowadays, polycrystalline diamond compact (PDC) cutters performance dropped and affects the performance of drilling efficiency. The objective of this project is to investigate the effect of PDC cutters geometry and optimize their geometry features. An intensive study in PDC cutters geometry would help complete the section with high penetration and low wear rate. Relatively deepened analysis was carried out and come out with four important geometries features that can help in improving the penetration and reduce wear rate. They are chamfer angle, back rake angle, side rake angle and diameter. An appropriate optimization method that effectively controls all influential geometries factors during PDC cutters manufacturing is therefore critical. By adopting L9 Taguchi OA, the simulation experiment is conducted by using explicit dynamics finite element analysis (FEA). A1B1C3D1 are identified as the optimal geometry. The set of optimum geometries is identified as the following: chamfer angle of 15°, back rake angle of 0°, side rake angle of 30°, a diameter of 8 mm. The optimized PDC bit is expected to drill with high ROP that can reduce the rig time which in its turn, may reduce the total drilling cost. © 2006-2016 Asian Research Publishing Network (ARPN).