Drill string torsional and longitudinal oscillation can significantly reduce axial drag in horizontal drilling. An improved theoretical model for the analysis of the frictional force was proposed based on microscopic contact deformation theory and a bristle model. The established model, an improved dynamic friction model established for drill strings in a wellbore, was used to determine the relationship of friction force changes and the drill string torsional vibration. The model results were in good agreement with the experimental data, verifying the accuracy of the established model. The analysis of the influence of drilling mud properties indicated that there is an approximately linear relationship between the axial friction force and dynamic shear and viscosity. The influence of drill string torsional oscillation on the axial friction force is discussed. The results indicated that the drill string transverse velocity is a prerequisite for reducing axial friction. In addition, low amplitude of torsional vibration speed can significantly reduce axial friction. Then, increasing the amplitude of transverse vibration speed, the effect of axial reduction is not significant. In addition, by involving general field drilling parameters, this model can accurately describe the friction behavior and quantitatively predict the frictional resistance in horizontal drilling.

This paper designs a new class of actuators for the downhole traction robot system to achieve high-accuracy transmission, which is realized by the planetary roller screw mechanism (PRSM). As the downhole environment is a non-structure one, which increases the difficulty of the load analyses and distributions of the downhole robot system to complete a predesigned mission. Traditional achievements about the mechanical behavior analyses of PRSM ignore the effects of radial loads and torque elastic deformation errors, which are inevitable for the downhole robot actuator, and the results of which would affect the load distribution and fatigue life of the PRSM-aided actuator. To assist the complex task, in this study the mechanical behavior analyses of PRSM for the downhole robot system are investigated by considering axial loads, torque elastic deformation errors, and radial loads. Moreover, the calculation models for contact load distribution and fatigue life are established by utilizing the equivalent contact load and Hertz contact theory. Two cases for the robot actuator in the downhole environment are addressed, the results of which indicate that the contact load change and decrease with the thread growth direction of the PRSM, the first several threads bore most of the loads, and the last several threads only took a few loads. Additionally, the fatigue life reduces sharply under the condition that the axial loads, radial loads, and rotation speeds increase. Compared with the other two effectors, the fatigue life is more sensitive to the radial loads. The results show the sustainability of the presented screw–roller–nut and provide a potential reference for the downhole robot actuator motion analyses.

Based on a brief overview on the determination methods of formation pressure and their features, the major principle of formation pressure testing while drilling (FPTWD) and existing physical simulation systems was introduced, and the deficiency of the existing physical simulation systems was also discussed. A laboratory high-precision physical simulation system was therefore developed to simulate the downhole testing environment and testing process of FPTWD. The present experimental system was designed to endure pressures up to 20,000 psi, and the relative control accuracy of pressure is approximately 0.02% FS. Two kinds of man-made specimens with the permeability of 10–110 mD were used to test the pressure response and to verify the present physical simulation system. The debugging results indicated that the variation amplitude under the stable condition is approximately 0.07 psi, 0.08 psi, 0.11 psi, and 0.11 kN for the annular pressure, pore pressure, confining pressure, and thrust force, respectively. Thus, the high control accuracy is approximately ±1.0 psi under the stable conditions. The experimental results indicated that the pressure drawdown declines rapidly in the stage of withdrawing formation fluids and then recovers slowly. The pressure drop amplitude also decreases with permeability, while the pressure buildup amplitude increases with permeability. The tendency of pressure change is nearly the same for both the present and the previous systems, and the pressure curve of the present system is much smoother and better than that of the previous system. The relative error of explaining formation pressure is less than 1% and 4% for the present and the previous systems, respectively. In addition, this physical simulation system has important applications to verify the interpretation model, to analyze pressure response recorded by FPTWD tools, to test the capability and design of FPTWD tools, and to calibrate the formation pressure, formation parameters, and instrument factors.