Optimization of Single-Tooth Rake Angle for Enhanced Cutting Performance in High-Strength Casing Section Milling

Yufeng Zeng; Chong Xie

doi:10.62051/ijmee.v6n3.09

Authors

Yufeng Zeng
Chong Xie

DOI:

https://doi.org/10.62051/ijmee.v6n3.09

Keywords:

Section Milling, High-strength Casing, Rake Angle Optimization, Cutting Force Reduction, Chip Morphology

Abstract

Section milling of high-strength casings in deep and ultra-deep wells faces significant challenges, including excessive cutting forces, rapid tool wear, and inefficient chip removal. This study proposes a novel cutting performance enhancement method through systematic optimization of the single-tooth rake angle. A 3D explicit dynamic finite element model was developed to simulate orthogonal cutting of P110 casing, validated by lathe experiments with triaxial force measurements. Results demonstrate that a rake angle of γ = 0° optimally balances cutting efficiency and chip control: it minimizes tangential and radial cutting forces, generates short C-shaped chips with 93% mud-carrying efficiency, and eliminates tool jamming risks. Negative rake angles (γ ≤ -2°) produced problematic continuous or powdery chips, while positive angles increased force variability. The 0° configuration reduced specific cutting energy and enhanced tool stability, directly contributing to extended tool life and operational safety. This work provides a foundational strategy for designing next-generation section milling tools targeting high-strength wellbore applications.

References

[1] Gajdzik, B., R. Wolniak, R. Nagaj, B. V Z Uromskait E Nagaj, and W.W. Grebski. 2024. The influence of the global energy crisis on energy efficiency: A comprehensive analysis. Energies, 17 (4), 947.

[2] Qin, Y., J. Feng, and G. Qin. 2015. The Research and Application of Cementing Techniques on Casing Cutting Window Sidetrack Drilling. 202--207.

[3] Afolabi, F., R. Lacy, R. Asher, and B. Butler. 2007. Rigless Installations of Safety Valves to Implement a Well-Integrity Campaign and Return Wells to Production.

[4] Kong, L., Y. Wang, H. Wang, B. Zhang, and C. Feng. 2024. Mathematical modeling of casing exit windowing by swirling abrasive jet. Geoenergy Science and Engineering 238:212869.

[5] Smalley, M.T., D.W. Teale, and M.A. Haq. 2017. Workover well operations to restore full reservoir access in an underground natural-gas-storage cavern: a case study for developing new technology in dual-string section milling methods.

[6] Tang, M., H. Li, S. He, J. Miao, B. Huang, L. He, and X. Zhou. 2022. Research and Development of High-Performance Section Milling Tool for $Phi$ 139.7-mm Casing. Arab J Sci Eng 47:12205--12222.

[7] Gajdos, M., T. Kristofic, S. Jankovic, G. Horvath, and I. Kocis. 2015. Use of plasma-based tool for plug and abandonment.

[8] Kang, H., J. Cho, J. Park, J. Jang, J. Kim, K. Kim, J. Rostami, and J. Lee. 2016. A new linear cutting machine for assessing the rock-cutting performance of a pick cutter. Int J Rock Mech Min Sci (1997) 88:129--136.

[9] Deshpande, K.M., M.A. Haq, S. Gajula, and D. Teale. 2016. Dual string section milling tool design optimisation using advanced numerical simulations.

[10] Neema, S., L. Singh, F. Chiquiza, J. First, C. Collier, T. Oo, K. Katla, and D. Martin. 2021. Data-Driven Performance Optimization in Section Milling.

[11] Wangsamulia, D., K. Pahlevi, S. Paulus, G. Aditya, H. Tanjung, and R. Dewanda. 2021. Optimising Depth Selection on Section Milling Operation to Secure Sustained Casing Pressure During Plug and Abandonment Operation.

[12] Xiao, S., F. Zhang, and Z. Liang. 2018. A mathematical casing cutting model and operation parameters optimization of a large-diameter deepwater hydraulic cutter. J Pet Sci Eng 162:76--83.

[13] Stowe, C., and A. Ponder. 2011. Performance advance in section milling technology.

[14] Cheng, Y., X. Gai, R. Guan, Y. Jin, and M. Lu. 2023a. Modeling of Dynamic Cutting Force considering Flank Wear and Analysis of Tool Wear Mechanism in Milling 508III Steel. Integr Ferroelectr 233:1--18.

[15] Zhou, X., S. He, M. Tang, Y. Li, G. Zhang, and X. Liu. 2022. Structural design and mathematical cutting model of hydraulic section milling for high-strength casings in small wellbores. J Pet Sci Eng 218:111044.

[16] Kong, C., Z. Liang, D. Zhang, and R. Cai. 2016. Research on cutting mechanics of window bit cutting teeth. Adv Mech Eng 8:1687814016662004.

[17] Johnson, G.R. 1983. A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures.

[18] Liu, J., Y. Bai, and C. Xu. 2014. Evaluation of ductile fracture models in finite element simulation of metal cutting processes. Journal of Manufacturing Science and Engineering 136:011010.

[19] Li, W., X. Ling, and H. Pu. 2020. Development of a cutting force model for a single PDC cutter based on the rock stress state. Rock Mech Rock Eng 53:185--200.

[20] Ni, P., Y. Wang, D. Tan, Y. Zhang, Z. Chen, Z. Wang, C. Yi, L. Shao, and Y. Lu. 2023. Research on optimization method of stainless steel sawing process parameters based on multi-tooth sawing force prediction model. The International Journal of Advanced Manufacturing Technology 128:4513--4533.