As deep oil and gas resources and Carbon Capture and Storage (CCS) are developed, enhancing drilling efficiency in hard rock formations has emerged as a critical technology in oil and gas extraction. The advancement of ultrasonic, high-frequency vibration rock-breaking technology significantly facilitates efficient rock crushing. When subjected to ultrasonic high-frequency vibrations, the rock’s response is a crucial issue in implementing ultrasonic vibration rock crushing technology. This study employed numerical simulation and theoretical deduction methods, utilizing a multi-physics approach that couples solid mechanics with pressure acoustics. It integrated information on common influencing parameters of ultrasonic generators and reservoir rock properties to establish model parameters, analyze simulation results, and perform theoretical deductions. The research investigated the response patterns of different-sized rock samples under high-frequency ultrasound vibration excitation across various frequencies, amplitudes, and confining pressure conditions. Through the development of a three-dimensional model and the application of principles from solid mechanics and elastoplasticity, the study derived equations that describe the resonance frequencies of rock blocks under confining pressure as functions of relevant rock parameters. The findings indicate that ultrasonic vibrations can effectively induce rock displacement. Under excitation frequency sources, the rock exhibits a natural frequency correlated with the rock sample size. When the excitation frequency approximates the natural frequency, the rock resonates. At this point, the rock’s surface displacement is maximal. The rock undergoes tensile stress, leading to stress concentration that facilitates rock damage and fragmentation. Increasing the excitation amplitude enhances rock crushing, as it amplifies the maximum surface displacement under the same frequency excitation. Confining pressure exerts an inhibitory effect on the rock’s vibration response, but it does not alter the resonance frequency of the rock sample, a fact verified by both numerical simulation and theoretical results. Based on the research findings in this paper, it can help to optimize the parameters of ultrasonic vibration rock breaking in field application to achieve the best rock-breaking effect.

To enhance the efficiency of the Stinger Polycrystalline Diamond Compact (PDC) cutter in breaking hard rocks, this study focuses on optimizing the cutter intrusion-cutting rock breaking parameters. A numerical calculation model for the rotational breaking of granite by a Stinger PDC cutter was established. A comprehensive statistical examination was performed to assess the influence of various factors on intrusion ability (IA), tangential force (TF), and mechanical specific energy (MSE). The Taguchi method was used to determine the optimal settings for each factor, while analysis of variance was employed to assess the significance and relative impact of these factors on the target outcomes. In addition, the multi-objective function was optimized using the gray relational analysis method. The primary process parameters obtained for the various performance characteristics are the cone top angle (α), the cone top radius (r), the cutter diameter (d), the cutter back inclination angle (β), and weight on bit (P). The impact ratios of these parameters are 6.20%, 7.66%, 3.93%, 17.20%, and 65.02%, respectively. The optimal geometrical parameters are α = 60°, r = 2 mm, and d = 15 mm, while the optimal working parameters are β = 30° and P = 800 N. In the optimal case, IA and MSE were reduced by 55.335% and 15.809%, respectively, compared to the initial case. Despite a 15.706% increase in TF, the overall GRG increased for all three evaluation criteria, with an overall increase in efficiency of 18.229%. The results of this paper can provide guidance for the design of Stinger cutter PDC drill bits.

In order to improve the erosion resistance of steel PDC (Polycrystalline Diamond Compact) bit under high-speed fluid flow conditions underground, it is necessary to develop a high-performance erosion-resistant coating. In this paper, laser cladding was used to prepare the new coating by modifying tungsten carbide with graphene. And the effects of tungsten carbide content and graphene content on the coating performance have been thoroughly studied and analyzed to obtain the optimal covering layer. The research results indicate that, for new coatings, 60% tungsten carbide and 0.3% graphene are the optimal ratios. After adding tungsten carbide, the hardness has significantly improved. However, when the tungsten carbide content further increases more than 30%, the increase in hardness is limited. In addition, when the content of graphene is more than 0.3%, the branched structure becomes thicker. In detail, this is a phenomenon where the segregation of Cr, Si, and W becomes very obvious again, and the segregation of Fe occurs at the Ni enrichment site. The research results contribute to the development and optimization of high-quality erosion-resistant coatings under the high-speed flow conditions in wellbore. These are of great significance for improving the efficiency of oil and gas exploration and development.

The application of ultra-high-pressure (UHP) water jets for rock slotting in the bottom hole has been recognized as a highly effective approach to enhance rock-breaking efficiency. However, the current downhole intensifiers are confronted with various limitations, including the short duration of UHP pulse water jet output and challenges in attaining both controllable and adjustable output frequencies, consequently leading to compromised slotting efficiency. In this study, a novel intensifier controlled by an electromagnetic valve was designed, and a visual test platform was constructed to investigate the output pressure characteristics and their influencing factors. The output characteristics of the intensifier consist of a mixed pulse jet composed of high-pressure and low-pressure jets, resulting in a square wave-like output waveform with an adjustable frequency. The output pressure characteristics of the intensifier are primarily influenced by the input pressure and the switching time of the electromagnetic valve, assuming that the structural parameters are constant. Increasing the input pressure raises the peak pressure, thereby enhancing the slotting capability of the jet stream. Aligning the switching time of the electromagnetic valve with the rotation period of the drill bit improves the slotting efficiency. In the lab tests, the output pressure of the intensifier was successfully increased to 118.2 MPa, with a sustained duration of a high-pressure jet segment for 2.1 s. These research findings offer a new method for enhancing drilling efficiency in deep hard rock formations.

In the process of oil and gas development and production, when the flow rate in the wellbore is large, the materials underground will be eroded, causing the operation to be unable to proceed smoothly and reducing the efficiency of oil and gas production. Therefore, optimizing the anti-erosion coating under high-speed flow conditions in wellbore is a very interesting thing. It can greatly improve operational efficiency. In this paper, laser cladding was used to prepare the new coating used in the PDC drill bit. Then, the effects of tungsten carbide and multi-layer graphene on the microstructure and properties of the tungsten carbide coating were studied. The research results indicate that, for new coatings, 60% tungsten carbide and 0.3% graphene are the optimal ratios. After adding WC, the hardness has significantly improved. However, when the WC content further increases more than 30%, the increase in hardness is relatively small. In addition, when the content of graphene is more than 0.3%, the branched structure became thicker, and not only the segregation of Cr, Si and W became very obvious again, but also the segregation of Fe occurred at the Ni enrichment site. The research results contribute to improving oil and gas production and operational efficiency under high-speed fluid flow conditions in the wellbore.