Performances of a Stinger PDC cutter breaking granite: Cutting force and mechanical specific energy in single cutter tests

The Stinger PDC cutter has high rock-breaking efficiency and excellent impact and wear resistance, which can significantly increase the rate of penetration (ROP) and extend PDC bit life for drilling hard and abrasive formation. The knowledge of force response and mechanical specific energy (MSE) for the Stinger PDC cutter is of great importance for improving the cutter's performance and optimizing the hybrid PDC bit design. In this paper, 87 single cutter tests were conducted on the granite. A new method for precisely obtaining the rock broken volume was proposed. The influences of cutting depth, cutting angle, and cutting speed on cutting force and MSE were analyzed. Besides, a phenomenological cutting force model of the Stinger PDC cutter was established by regression of experimental data. Moreover, the surface topography and fracture morphology of the cutting groove and large size cuttings were measured by a 3D profilometer and a scanning electron microscope (SEM). Finally, the rock-breaking mechanism of the Stinger PDC cutter was illustrated. The results indicated that the cutting depth has the greatest influence on the cutting force and MSE, while the cutting speed has no obvious effects, especially at low cutting speeds. As the increase of cutting depth, the cutting force increases linearly, and MSE reduces with a quadratic polynomial relationship. When the cutting angle raises from 10° to 30°, the cutting force increases linearly, and the MSE firstly decreases and then increases. The optimal cutting angle for breaking rock is approximately 20°. The Stinger PDC cutter breaks granite mainly by high concentrated point loading and tensile failure, which can observably improve the rock breaking efficiency. The key findings of this work will help to reveal the rock-breaking mechanisms and optimize the cutter arrangement for the Stinger PDC cutter.

Research Progress on High Specific Energy Cathode Materials for Rechargeable Lithium Sulfur Batteries

An overview of the developing survey, research actuality and the future development of high specific energy and power lithium sulfur rechargeable batteries was presented systemically. By introducing the character of sulfur composite material and discussing some promising cathode materials, it may provide some foundation for people to go deep into researching and empoldering the sulfur composite material.

Specific Energy Consumption Analysis Model and Its Application in Typical Steel Manufacturing Process

Theoretical minimum and actual specific energy consumptions （SEC） of typical manufacturing process （SMP） were studied. Firstly, a process division of a typical SMP in question was conducted with the theory of SEC analysis. Secondly, an exergy analysis model of a subsystem consisting of several parallel processes and a SEC analysis model of SMP were developed. And finally, based on the analysis models, the SEC of SMP was analyzed by means of the statistical significance. The results show that the SEC of typical SMP comprises the theoretical minimum SEC and the additional SEC derived from the irreversibility~ and the SMP has a theoretical minimum SEC of 6.74 GJ/t and an additional SEC of 19.32 GJ/t, which account for 25.88% and 74.12% of the actual SEC, respectively.

Energy dissipation mechanism and ballistic characteristic optimization in foam sandwich panels against spherical projectile impact

This study systematically examines the energy dissipation mechanisms and ballistic characteristics of foam sandwich panels(FSP)under high-velocity impact using the explicit non-linear finite element method.Based on the geometric topology of the FSP system,three FSP configurations with the same areal density are derived,namely multi-layer,gradient core and asymmetric face sheet,and three key structural parameters are identified:core thickness(t_(c)),face sheet thickness(t_(f))and overlap face/core number(n_(o)).The ballistic performance of the FSP system is comprehensively evaluated in terms of the ballistic limit velocity(BLV),deformation modes,energy dissipation mechanism,and specific penetration energy(SPE).The results show that the FSP system exhibits a significant configuration dependence,whose ballistic performance ranking is:asymmetric face sheet>gradient core>multi-layer.The mass distribution of the top and bottom face sheets plays a critical role in the ballistic resistance of the FSP system.Both BLV and SPE increase with tf,while the raising tcor noleads to an increase in BLV but a decrease in SPE.Further,a face-core synchronous enhancement mechanism is discovered by the energy dissipation analysis,based on which the ballistic optimization procedure is also conducted and a design chart is established.This study shed light on the anti-penetration mechanism of the FSP system and might provide a theoretical basis for its engineering application.

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

Specific energy consumption is an important indicatorfora better understanding of the machinability of materials.The present study aims to estimate the specific energy consumption for abrasive metal cutting with ultrathin discs at comparatively low and medium feed rates.Using an experimental technique,the cutting power was measured at four predefined feed rates for S235JR,intermetallic Fe-Al(40%),and C45K with different thermal treatments.The variation in the specific energy consumption with the material removal rate was analyzed through an empirical model,which enabled us to distinguish three phenomena of energy dissipation during material removal.The thermal treatment and mechanical properties of materials have a significant impact on the energy consumption pattern,its corresponding components,and cutting power.Ductile materials consume more specific cutting energy than brttle materials.The specific cutting energy is the minimum energy required to remove the material,and plowing energy is found to be the most significant phenomenon of energy dissipation.

Analysis of minimum specific energy consumption and optimal transport concentration of slurry pipeline transport systems

Slurry pipeline transport is widely used in several industrial processes.Calculating the specific power consumption(SPC)and determining the best working conditions are important for the design and operation of transportation systems.Based on the Shanghai Jiao Tong University high-concentration multi-sized slurry pressure drop(SJTU-HMSPD)pipeline-resistance-calculation model,the SJTU-SPC model for calculating the power required to transport a unit volume of solid materials over a unit pipeline length is established for a slurry transport system.The said system demonstrates a uniformity coefficient in the 1.26–7.98 range,median particle size of 0.075–4 mm,particle volume concentration of 10–60%,and pipeline diameter of 0.203–0.8 m.The results obtained were successfully verified against existing experimental data.The influence of parameters,such as particle-gradation uniformity coefficient,median particle size,pipe diameter,and particle volume concentration,on the SPC were analysed.The results revealed that the greater is the uniformity coefficient,the smaller is the minimum specific energy consumption and the larger the optimal transport concentration for a constant,median particle size slurry.As observed,the optimal transport concentration for broad-graded sand equalled approximately 48%.These results supplement the conclusions of existing research,indicating that the optimal transport concentration is approximately 30%and provides theoretical support for high concentration transportation of broad graded slurry.

Meta-analysis of CO_(2) conversion,energy efficiency,and other performance data of plasma-catalysis reactors with the open access PIONEER database

This paper brings the comparison of performances of CO_(2)conversion by plasma and plasma-assisted catalysis based on the data collected from literature in this field,organised in an open access online database.This tool is open to all users to carry out their own analyses,but also to contributors who wish to add their data to the database in order to improve the relevance of the comparisons made,and ultimately to improve the efficiency of CO_(2)conversion by plasma-catalysis.The creation of this database and database user interface is motivated by the fact that plasma-catalysis is a fast-growing field for all CO_(2)conversion processes,be it methanation,dry reforming of methane,methanolisation,or others.As a result of this rapid increase,there is a need for a set of standard procedures to rigorously compare performances of different systems.However,this is currently not possible because the fundamental mechanisms of plasma-catalysis are still too poorly understood to define these standard procedures.Fortunately however,the accumulated data within the CO_(2)plasma-catalysis community has become large enough to warrant so-called“big data”studies more familiar in the fields of medicine and the social sciences.To enable comparisons between multiple data sets and make future research more effective,this work proposes the first database on CO_(2)conversion performances by plasma-catalysis open to the whole community.This database has been initiated in the framework of a H_(2)0_(2)0 European project and is called the“PIONEER Data Base”.The database gathers a large amount of CO_(2)conversion performance data such as conversion rate,energy efficiency,and selectivity for numerous plasma sources coupled with or without a catalyst.Each data set is associated with metadata describing the gas mixture,the plasma source,the nature of the catalyst,and the form of coupling with the plasma.Beyond the database itself,a data extraction tool with direct visualisation features or advanced filtering functionalities has been developed and is available online to the public.The simple and fast visualisation of the state of the art puts new results into context,identifies literal gaps in data,and consequently points towards promising research routes.More advanced data extraction illustrates the impact that the database can have in the understanding of plasma-catalyst coupling.Lessons learned from the review of a large amount of literature during the setup of the database lead to best practice advice to increase comparability between future CO_(2)plasma-catalytic studies.Finally,the community is strongly encouraged to contribute to the database not only to increase the visibility of their data but also the relevance of the comparisons allowed by this tool.

THEORETICAL CALCULATION OF SPECIFIC INTERFACIALENERGY OF SEMICOHERENT INTERFACE BETWEEN MICROALLOY CARBONITRIDES AND AUSTENITE

According to the misfitting dislocation theory,a method of theoretical calculation was devel- oped for the specific energy of the semicoherent interface between microalloy carbonitrides and austenite matrix.The calculating formulae were derived and the results were satisfactorily applied on the research works.

Cutting force and specific energy for rotary ultrasonic drilling based on kinematics analysis of vibration effectiveness

Rotary ultrasonic drilling(RUD)has become an effective approach for machining advanced composites which are widely using in the field of aeronautics.The cutting kinematics and the corresponding material removal mechanisms are distinct in different drilling areas during RUD.However,these fundamentals have not been fully considered in the existing studies.In this research,two distinct forms of interaction induced by ultrasonic vibration were considered as impact-separation and vibratory lapping between the abrasives and workpiece.And the conditions to guarantee the effectiveness of these interactions were obtained to eliminate diminishing effects of ultrasonic vibration.Based on indentation fracture theory,the penetration depth of abrasives and the axial drilling force model was derived for RUD.The verification tests of C/SiC composites resulted in a prediction error within 15%.Due to the minimal volume of material removed during each vibration cycle,the drilling force was more stable in vibration assisted mode.The specific drilling energy of RUD was firstly calculated based on the measured drilling load.It was found the drilling parameters should be matched with vibration frequency and amplitude to make better usage of the advantages of ultrasonic vibration,which is critical in the vibration assisted processing of advanced materials.

On Energy Assessment of Titanium Alloys Belt Grinding Involving Abrasive Wear Effects

Improved energy utilisation,precision,and quality are critical in the current trend of low-carbon green manufactur-ing.In this study,three abrasive belts were prepared at various wear stages and characterised quantitatively.The effects of abrasive belt wear on the specific grinding energy partition were investigated by evaluating robotic belt grinding of titanium plates.A specific grinding energy model based on subdivided tangential forces of cutting and sliding was developed for investigating specific energy and energy utilisation coefficient EUC.The surface mor-phology and Abbott–Firestone curves of the belts were introduced to analyse the experimental findings from the per-spective of the micro cutting behaviour.The specific grinding energy increased with abrasive belt wear,especially when the belt was near the end of its life.Moreover,the belt wear could lead to a predominance change of sliding and chip formation energy.The highest EUC was observed in the middle of the belt life because of its retained sharp cutting edge and uniform distribution of the grit protrusion height.This study provides guidance for balancing the energy consumption and energy utilization efficiency of belt grinding.

Fragmentation Energy-Saving Theory of Full Face Rock Tunnel Boring Machine Disc Cutters

Attempts to minimize energy consumption of a tunnel boring machine disc cutter during the process of fragmentation have largely focused on optimizing disc- cutter spacing, as determined by the minimum specific energy required for fragmentation; however, indentation tests showed that rock deforms plastically beneath the cutters. Equations for thrust were developed for both the traditional, popularly employed disc cutter and anew design based on three-dimensional theory. The respective energy consumption for penetration, rolling, and side-slip fragmentations were obtained. A change in disc-cutter fragmentation angles resulted in a change in the nature of the interaction between the cutter and rock, which lowered the specific energy of fragmentation. During actual field excavations to the same penetration length, the combined energy consumption for fragmentation using the newly designed cutters was 15% lower than that when using the traditional design. This paper presents a theory for energy saving in tunnel boring machines. Investigation results showed that the disc cutters designed using this theory were more durable than traditional designs, and effectively lowered the energy consumption.

Boosting energy-storage capability in carbon-based supercapacitors using low-temperature water-in-salt electrolytes

Supercapacitors(SCs) are high-power energy storage devices with ultra-fast charge/discharge properties.SCs using concentrated aqueous-based electrolytes can work at low temperatures due to their intrinsic properties, such as higher freezing point depression(FPD) and robustness. Besides the traditional organic-and aqueous-based(salt-in-water) electrolytes used in SCs, water-in-salt(WISE) sodium perchlorate electrolytes offer high FPD, non-flammability, and low-toxicity conditions, allowing the fabrication of safer, environmentally friendly, and more robust devices. For the first time, this work reports a comprehensive study regarding WISE system’s charge-storage capabilities and physicochemical properties under low-temperature conditions(T < 0 ℃) using mesoporous carbon-based electrodes. The effect of temperature reduction on the electrolyte viscosity and electrical properties was investigated using different techniques and the in-situ(or operando) Raman spectroscopy under dynamic polarization conditions.The cell voltage, equivalent series resistance, and specific capacitance were investigated as a function of the temperature. The cell voltage(U) increased ~ 50%, while the specific capacitance decreased ~20%when the temperature was reduced from 25 ℃ to -10 ℃. As a result, the maximum specific energy(E = CU^(2)/2) increased ~ 100%. Therefore, low-temperature WISEs are promising candidates to improve the energy-storage characteristics in SCs.

Optimization Design of an Embedded Multi-Cell Thin-Walled Energy Absorption Structures with Local Surface Nanocrystallization

Bymeans of the local surface nanocrystallization that enables to change the material on local positions,an innovative embedded multi-cell(EMC)thin-walled energy absorption structures with local surface nanocrystallization is proposed in this paper.The local surface nanacrystallization stripes are regarded as the moving morphable components in the domain for optimal design.Results reveal that after optimizing the local surface nanocrystallization layout,the specific energy absorption(SEA)is increased by 50.78%compared with the untreated counterpart.Besides,in contrast with the optimized 4-cell structure,the SEA of the nanocrystallized embedded 9-cell structure is further enhanced by 27.68%,in contrast with the 9-cell structure,the SEA of the nanocrystallized embedded clapboard type 9-cell structure is enhanced by 3.61%.Thismethod provides a guidance for the design of newenergy absorption devices.

Viability of Harvesting Salinity Gradient (Blue) Energy by Nanopore-Based Osmotic Power Generation

The development of novel materials with ion-selective nanochannels has introduced a new technology for harvesting salinity gradient(blue)energy,namely nanopore power generators(NPGs).In this study,we perform a comprehensive analysis of the practical performance of NPG in both coupon-size and module-scale operations.We show that although NPG membrane coupons can theoretically generate ultrahigh power density under ideal conditions,the resulting power density in practical operations at a coupon scale can hardly reach 10 W·m^(-2) due to concentration polarization effects.For module-scale NPG operation,we estimate both the power density and specific extractable energy(i.e.,extractable energy normalized by the total volume of the working solutions),and elucidate the impact of operating conditions on these two metrics based on the interplay between concentration polarization and extent of mixing of the high-and low-concentration solutions.Further,we develop a modeling framework to assess the viability of an NPG system.Our results demonstrate that,for NPG systems working with seawater and river water,the gross specific extractable energy by the NPG system is very low(~0.1 kW?h?m?3)and is further compromised by the parasitic energy consumptions in the system(notably,pumping of the seawater and river water solutions and their pretreatment).Overall,NPG systems produce very low net specific extractable energy(<0.025 kW?h?m?3)and net power density(<0.1 W?m?2).Our study highlights the significant practical limitations in NPG operations,casting doubt on the viability of NPG as a technology for blue energy harvesting.

Rock breaking performance of the newly proposed unsubmerged cavitating abrasive waterjet

To improve the rock breaking ability, cavitating waterjet and abrasive waterjet are combined by using a coaxial low-speed waterjet generated around the periphery of a high-speed abrasive waterjet, and a new type of waterjet called unsubmerged cavitating abrasive waterjet(UCAWJ) is thus produced. The rock breaking performance of UCAWJ was compared with submerged cavitating abrasive waterjet(SCAWJ)and unsubmerged abrasive waterjet(UAWJ) by impinging sandstone specimens. Moreover, the effects of jet pressure, standoff distance, abrasive flow rate and concentration were studied by evaluating the specific energy consumption, and the area, depth, and mass loss of the eroded specimen. The results show that the artificially generated submerged environment in UCAWJ is able to enhance the rock breaking performance under the same operating parameters. Furthermore, the rock breaking performance of UCAWJ is much better at higher jet pressures and smaller standoff distances when compared with UAWJ. The greatest rock breaking ability of UCAWJ appears at jet pressure of 50 MPa and standoff distance of 32 mm, with the mass loss of sandstone increased by 370.6% and the energy dissipation decreased by 75.8%. In addition, under the experimental conditions the optimal abrasive flow rate and concentration are 76.5 m L/min and 3%, respectively.

Comparative Study of the Rock-breaking Mechanism of a Disc Cutter and Wedge Tooth Cutter by Discrete Element Modelling

The operation of a shield tunnel boring machine(TBM)in a high-strength hard rock stratum results in significant cutter damage,adversely affecting the thrust and torque of the cutter head.Therefore,it is very important to carry out the research on the stress characteristics and optimize the cutter parameters of cutters break high-strength hard rock.In this paper,the rock-breaking performance of cutters in an andesite stratum in the tunnel of Qingdao Metro Line No.8 was investigated using the discrete element method and theoretical analysis.The rock-breaking processes of a disc cutter and wedge tooth cutter were simulated by software particle flow code PFC^(3D),and the rock-breaking degree,stress of the cutter,and rock-breaking specific energy were analyzed.The rock damage caused by the cutter in a specific section was divided into three stages:the advanced influence,crushing,and stabilizing stages.The rock-breaking degree and the tangential and normal forces of the wedge tooth cutter are larger than that of the disc cutter under the same conditions.The disc cutter(wedge tooth cutter)has the highest rock-breaking efficiency at a cutter spacing of 100 mm(110 mm)and a penetration depth of 8 mm(10 mm),and the rock-breaking specific energy is 11.48 MJ/m^(3)(12.05 MJ/m^(3)).Therefore,two types of cutters with different penetration depths or cutter spacing should be considered.The number of teeth of wedge tooth cutters can be increased in hard strata to improve the rock-breaking efficiency of the shield.The research results provide a reference for shield cutterhead selection and cutter layout in similar projects.

Application of wavelet to strength log from scratch test

This paper proposes a methodology to construct logs of rock strength from the cutting force signal recorded in scratch tests conducted in the ductile regime.The approach,which is based on the application of discrete wavelet transforms,recognizes the existence of two length scales[c and[r.The strength length scale[c represents the length over which it is meaningful to measure strength,while the repeatability length scale[r is related to the resolution at which the force signal must be observed to become insensitive to the stochastic micro-failure events triggered by the motion of the cutter.It is postulated that the original cutting force signal,assumed to be sampled at a high enough frequency,can be decomposed into a deterministic signal intrinsic to the rock and a stochastic one resulting from discrete rock failure events.The technique of multiresolution analysis based on the maximal overlap discrete wavelet transform is applied as a low-pass filter to the original cutting force signals so as to wipe out the high-frequency components associated with the stochastic rock failure events.A criterion to determine the optimum cutoff frequency of the low-pass filter and the corresponding repeatability length scale is discussed in terms of the correlation coefficients between different filtered signals.It is shown that the low-pass filtered signals obtained at the optimum cutoff frequency have two salient features:(i)repeatability over different tests conducted at the same depth of cut on the same sample,and(ii)variability along the cutting distance.The excellent repeatability reveals that the deterministic background trend of the original force signals is relevant to the rock strength property,and the variability of the background trend captures the spatial variation of the rock strength.

The rock breaking and ROP increase mechanisms for single-tooth torsional impact cutting using DEM

Torsional impact drilling is a new technology which has the advantages of high rock-breaking efficiency and a high rate of penetration(ROP).So far,there is no in-depth understanding of the rock-breaking mechanism for the ROP increase from torsional impact tools.Therefore,it has practical engineering significance to study the rock-breaking mechanism of torsional impact.In this paper,discrete element method(DEM)software(PFC2 D)is used to compare granite breaking under the steady and torsional impacting conditions.Meanwhile,the energy consumption to break rock,microscopic crushing process and chip characteristics as well as the relationship among these three factors for granite under different impacting frequencies and amplitudes are discussed.It is found that the average cutting force is smaller in the case of torsional impact cutting(TIC)than that in the case of steady loading.The mechanical specific energy(MSE)and the ratio of brittle energy consumption to total energy are negatively correlated;rock-breaking efficiency is related to the mode of action between the cutting tooth and rock.Furthermore,the ROP increase mechanism of torsional impact drilling technology is that the ratio of brittle energy consumption under the TIC condition is larger than that under a steady load;the degree of repeated fragmentation of rock chips under the TIC condition is lower than that under the steady load,and the TIC load promotes the formation of a transverse cracking network near the free surface and inhibits the formation of a deep longitudinal cracking network.

Evaluation of boring machine performance with special reference to geomechanical characteristics

The duration of tunneling projects mostly depends on the performance of boring machines. The performance of boring machines is a function of advance rate, which depends on the machine characterizations and geomechanical properties of rock mass. There were various theoretical and empirical models for estimating the advance rate. In this paper, after determining the geomechanical properties of rock mass encountered in the Isfahan metro tunnel, the performance of the roadheader and tunnel boring machine （TBM） were then evaluated using various models. The calculation results show that the average instantaneous cutting rate of the roadheader in sandstone and shale are 42.8 and 74.5 m^3/h respectively. However the actual values in practice are 34.2 and 51.3 m^3/h. The operational cutting rate of the roadheader in sandstone and shale are 8.2 and 9.7 m^3/h respectively, but the actual values are 6.5 and 6.7 m^3/h. The penetration rate of the TBM in shale is predicted to be 50-60 mm/round.

Experimental study on specific grinding energy and particle size distribution of maize grain,stover and cob

Reducing the particle size of biomass is of great significance for rational and efficient utilization of biomass.In this study,maize grain,stover,and cob were comminuted at different speeds(2000-2800 r/min)by hammer mill with a mesh size of 2.8 mm.The mechanical energy for smashing three selected samples was obtained directly through the sensor and data testing system.Experimental results demonstrated that the maize cob had the highest total specific energy while the maize grain had the lowest(135.83-181.10 kW·h/t and 27.08-36.23 kW·h/t,respectively).In addition,for the same material,higher hammer mill speed generated more specific energy consumption.And the effective specific energy of maize stover had a similar trend to the total specific one.However,the effective specific grinding energy of maize cob and grain increased initially and then decreased with the increase of rotating speed.The fitting curves of the specific energy to mill speeds were determined,and the range of determination coefficients of the regression equation was 0.933-0.996.Particle size distribution curves were drawn by sieving the pulverized particles of the three samples based on a series of standard sieves.Fourteen relevant parameters characterizing the particle size distribution were calculated according to the screening data.Calculation results demonstrated that larger rotational speed leads to smaller particle sizes.Combining the size parameters,distribution parameters,and shape parameters,it was found that the distributions of the three samples all exhibit a distribution of“well-graded fine-skewed mesokurtic”.The Rosin-Rammler function was considered to be suitable for characterizing the particle size distribution of maize grain,stover,and cob particles with a coefficient of determination between 0.930 and 0.992.