Wear morphology analysis and structural optimization of cone bit bearing seals

Abstract

Purpose This paper aims to clarify the relationship between the cone bit seal failure and the down-hole drilling fluid pressure and high temperature that occur during ultra-deep well drilling. It proposes that the contact pressure distribution under low pressure conditions is favourable for lubrication and the seal inner wear is serious under high pressure conditions. Furthermore, the more reliable cone bit seal can be obtained using the back propagation (BP) neural network and genetic algorithm (GA) to reduce the drilling cost. Design/methodology/approach The wear morphologies of the seal surface were analyzed using Contour GT-K to determine the seal contact pressure distribution. Then, the influences of the drilling fluid pressure and high temperature on the metal seal interface were analyzed using finite element method. The structural parameters of the seal under high pressure were optimized based on the BP neural network and GA. Findings This paper proposes that the inner seal contact pressure increases rapidly with an increase in the drilling fluid pressure. The design parameters of the seal components should be adjusted reasonably to ensure that the outer contact pressure is greater than the inner contact pressure, which is advantageous for forming a lubricant film on the inner side of the seal. The uneven temperature distribution of the seal surface will further aggravate seal failure. Originality/value Study on the bit seal with good property is significant in drilling application, and the optimized seal can prolong the cone bit life.