Reducing the heat loss in wellbore is the key for efficient development of geothermal resource. It is a reliable solution to establish a long-term stable wellbore with good thermal insulation through cementing. In this paper, the cement-based composite thermal insulation material was prepared by using cement as the cementing material, hollow glass beads, foaming agent and stabilizer as main raw materials, and other conventional admixtures. Foams and hollow glass beads can introduce gas with low thermal conductivity into cement, so as to improve the thermal insulation of composite material. Foams are produced by chemical forming process, using foaming agent, which is prepared according electrochemistry and thermodynamics, and the foam stabilizer helps foam distribute in cement slurry stably and uniformly. 10–13% hollow glass beads can significantly reduce the thermal conductivity of hardened cement, without significant adverse effects on the rheology and strength of the material. The thermal conductivity of the composite thermal insulation material can be as low as 0.2998 W·(m·K)⁻¹, which is 62% lower than that of conventional cement, while the compressive strength is 6.10 MPa, meeting the engineering requirement. A thermal-conductivity prediction method is proposed correspondingly based on Maxwell model, and the prediction error of the newly established model is within 2%. This research can provide technical support for efficient development of geothermal resources.

In a roller bit, the flat rubber ring (FRR) often needs to apply a certain amount of compression to ensure that its rotation and static sealing surfaces can be stably sealed. For the predicted Mises stress, values smaller than the actual Mises stress due to soft single-axis compression (SAC) stress are predicted by the Yeoh (N = 3) model. To more reasonably predict stress under the static compression of the FRR in the roller bit, the sealing effect of the FRR based on the SAC contact stress and the calculated Mises stress was evaluated by the Yeoh_revised model. Based on the assumption that hydrogenated nitrile-butadiene rubber (HNBR) is isotropic and incompressible, first, we derived the fitting formulas for three types of constitutive models and the Jacobi matrix of the Yeoh_revised model and developed hyperelastic constitutive subroutines. Simultaneously, the accuracy of three models (Yeoh, Yeoh_revised and Ogden) was evaluated by the goodness of fit (R²) to data from three kinds of tensile experiment tests. The highest R² is 0.9771 with the Yeoh_revised model, which merges the advantages of the other two fitting models and effectively improves the Yeoh model’s soft property of SAC contact stress. Additionally, by measuring on-site FRR wear, the maximum Mises stress on the sealing surface calculated based on the Yeoh_revised model is about twice that of the Yeoh model, and the maximum Mises stress on the rotation contact sealing surface is higher than that on the outside (static sealing) surface, which makes the aging of the rotation surface more severe. Thus, it was demonstrated that, on the premise of ensuring FRR sealing contact stress, the Yeoh_revised model can more reasonably predict the sealing effect of the FRR to more precisely calculate Mises stress than the Yeoh model. This also contributes to FRR structure optimization to prolong the service life of the FRR in the roller bit.