Arjstte 01 003

Advanced Research Journals of Science and Technology

ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY

(ARJST)

MODELING AND MATERIAL OPTIMIZATION OF A BBC 120F ROCK DRILL TOOL BIT

2349-9027

Adamson1, Miller2, 1 Research Scholar, Department of Thermal Engineering,University of Nigde, Geological Engineering, Kampus, Nigde, Turkey.

2 Professor , Department of Thermal Engineering, University of Nigde, Geological Engineering, Kampus, Nigde, Turkey.

Abstract Rough drill is device which is used to make holes or to drill the rocks in mining units. The use these type of drilling units to make holes in mining area to insert gelatensticks . this drill bit should have high strength.

The aim of the project is to model and to reduce the cost of the project. In this project we are analyzing this object using existing material and new suitable materials.

Generally these tools are manufactured with mild steel in this project. We are conducting structural model and harmonic analysis using mild steel and also we are applying different type of suitable material for the same, Modeling tool bit using 3D parametric software proe/engineer.

In the next step we are analyzing the model with existing material In the next step we are conducting analysis with diff suitable materials (one ofter completion of litaracher survy) Then we compare the displacement , stress and frequency values between analyzed materials to suggest best material for the road drill bit.

*Corresponding Author: Adamson , Research Scholar, Department of Thermal Engineering, University of Nigde, Geological Engineering, Kampus, Nigde, Turkey.

Published: October 16, 2014 Review Type: peer reviewed Volume: I, Issue : II

Citation: Adamson,Research Scholar (2014) MODELING AND MATERIAL OPTIMIZATION OF A BBC 120F ROCK DRILL TOOL BIT INTRODUCTION This MIT study characterizes the requirements on new fast and ultra-deep boring technology as follows: • the price of boring rises linearly with depth • bore axis with neutral floating • the possibility to make vertical or inclined bores up to 10 km deep • the possibility to make large diameter bores – even 5 times larger than on the ground compared to today drilling technologies • casing formed on site in the borehole Examples of new drilling technologies There are more than 20 research efforts solving innovative drilling technology such as: laser, spallation, plasma, electron beam, pallets, enhanced rotary, electric spark and discharge, electric arc, water jet erosion, ultrasonic, chemical, induction, nuclear, forced flame explosive, turbine, high frequency, microwave, heating/cooling stress, electric current and several other. The most promising solutions are mentioned below:

1. Hydrothermal spallation – Thermal spallation drilling uses a large, downhole burner, much like a jet engine, to apply a high heat flux to the rock face. This drilling technology is based on thermal processes of rock spallation and fusion.

2. Chemical plasma – is based on crushing by high-speed combustion, but nitric acid as oxidizing agent instead of oxygen.

3. Erosion - most patents refer to water jet rock cutting.

Different modification variants are described, e.g. utilization of cavitation, turbulent processes, combination with mechanical processes, etc.

4. Laser - during the recent decade intense research has been made into utilization of high energy laser beams for rock disintegration. Primarily conversion of military equipment is concerned. Laser energy is used for the process of thermal spallation, melting, or evaporation of rock.

5. Electric discharge - The methods utilizing electric discharge are based on long-term experience gained in other application areas.

6. Electrical plasma - is based on crushing by irradiation of plasma with high temperature up to 20 000°C 7. Direct transfer of heat - This technology is based on electrically melting rock at 1400°C; lava gravel will float to top; bore hole walls are of glass of surrounding rock.

Cost decreases with depth, with no limit on depth of bore hole. Bore diameters from 1m to 10m. Recovery of energy used to melt rock.

TAP HOLE DRILLING MACHINE Tap hole treatment plays the role once the melt in the furnace is ready for tapping. Smelting process efficiency is determined in two parts.

First part efficiency depends on • Furnace design parameters.

• Appropriate raw material.

• Accurate weighing, batching and feeding system

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Advanced Research Journals of Science and Technology

• Proper process control to achieve desired slag and metal composition.

Second part efficiency depends on post tap hole processes comprising of • Tap hole installation. (location and refractory lining around tap holes) • Repair of tap hole.

• Suitable tapping platform.

• Drilling machine for drilling the tap hole prior to oxygen lancing.

• Mud gun for proper closing of the tap hole.

• Receptacles for collection of liquid metal and slag.

• Skimming of floating slag on hot metal prior to casting.

• Casting of alloy in safe, economical and environmentally acceptable manner achieiving compact structure of metal.

• Method for slag disposal and/or utilization • Crushing, sizing and handling of finished product.

So for tapping we use tap hole drilling machine.

MODEL OF ROCK DRILL

FERRO ALLOYS Ferro Alloys are used as inputs in the manufacture of iron and steel for removal of oxygen and imparting specific properties. These are alloys of iron and elements like manganese, silicon, chromium, etc. While manganese and silicon alloys impart strength and hardness and act as powerful deoxidizing agents, chromium alloys make steel resistant to corrosion and heat. Typical examples of end products comprise rail road rails, structural steel, automobile bodies, etc. for manganese alloys and stainless steel utensils, cutlery, watch bodies, dairy equipment, hand railings, etc.

Silico manganese

Ferro manganese

Ferro chrome

INTRODUCTION TO CAD Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and designdocumentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provide the user with input-tools for the purpose of streamlining design processes; drafting, documentation, and manufacturing processes. CADD output is often in the form of electronic files for print or machining operations. The development of CADD-based software is in direct correlation with the processes it seeks to economize; industry-based software (construction, manufacturing, etc.) typically uses vector-based (linear) environments whereas graphic-based software utilizes rasterbased (pixelated) environments.

CADD environments often involve more than just shapes.

As in the manual drafting of technical and engineering drawings, the output of CAD must convey information, such as materials, processes, dimensions, and tolerances, according to application-specific conventions.

INTRODUCTION TO FEA Finite Element Analysis (FEA) was first developed in 1943

by R. Courant, who utilized the Ritz method of numerical analysis and minimization of variation calculus to obtain approximate solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J. Turner, R. W. Clough, H. C. Martin, and L. J. Top established a broader definition of numerical analysis. The paper centered on the "stiffness and deflection of complex structures".

By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries. Since the rapid decline in the cost of computers and the phenomenal increase in computing power, FEA has been developed to an incredible precision. Present day supercomputers are now able to produce accurate results for all kinds of parameters.

INTRODUCTION TO ANSYS ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very small pieces (of user-designated size) called elements.

The software implements equations that govern the behaviour of these elements and solves them all; creating a comprehensive explanation of how the system acts as a whole. These results then can be presented in tabulated or graphical forms. This type of analysis is typically used 8

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for the design and optimization of a system far too complex to analyze by hand. Systems that may fit into this category are too complex due to their geometry, scale, or governing equations.

Thermal Gradient

ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics and Chemistry departments.

ANSYS provides a cost-effective way to explore the performance of products or processes in a virtual environment. This type of product development is termed virtual prototyping.

With virtual prototyping techniques, users can iterate various scenarios to optimize the product long before the manufacturing is started. This enables a reduction in the level of risk, and in the cost of ineffective designs. The multifaceted nature of ANSYS also provides a means to ensure that users are able to see the effect of a design on the whole behavior of the product, be it electromagnetic, thermal, mechanical etc.

COUPLED FIELD ANALYSIS OF ROCK DRILL EXSISTING MODEL

Thermal Flux

Imported Model from Pro/Engineer

Nodal Temperature

RESULTS TABLE MS-MS

MS-TI

MS-GRAPHITE

NODEL TEMP

1873

1873

1873

THERMAL GRADIENT

805.675

915.815

819.738

THERMAL FLUX

40.2837

15.5688

19.6737

DISPLACEMENT

0.054578

0.063307

0.160594

STRESS

0.862747

0.694327

2.14763

CONCLUSION In this project we have done the optimization of rock drill tool head to improve life of the tool.

We have observed that toll is having thermal creep problems due to that end-users are replacing the head for each work.

In this project we have modified the head of the tool bit and also we have investigated on different materials.

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Advanced Research Journals of Science and Technology

First we have prepared assembly model of normal and modified models in pro/engineer software.

Then we have imported those models to ansys to analyze the structural and thermal properties by applying MS, TITANIUM & GRAPHITE for the tool head.

In the couple field analysis (combination of static and thermal) we got the stress, displacement, gradient and heat flux values.

By comparing those results we conclude that modified model with titanium material gives more life than previous model.

References HOWARTH, D.F., and ROWLAND, J.C. Quantitative assessment of rock texture and correlation with drillability and strength properties. Rock Mech. and Rock Eng., 1987, 20, pp. 57–85.

KAHRAMAN, S. Rotary and percussive drilling prediction using regression analysis. Int. J. Rock Mech. Min. Sci., 1999, 36, pp. 981–989.

KAHRAMAN, S., BALCHI C., YAZICHI, S. and BILGIN, N. Prediction of the penetration rate of rotary blast hole drills using a new drillability index. Int. J. Rock Mech. Min. Sci., 2000, 37, pp. 729–43.

KAHRAMAN, S., Correlation of TBM and drilling machine performances with rock brittleness. Eng. Geol., 2002, 65, pp. 269–283.

Karpuz, C., PASAMEHMETOGLU, A.G., DINCER, T., and MUFTUOGLU, Y. Drillability studies on the rotary blast hole drilling of lignite overburden series, Int. J. Surface Min. Recl., 1990, 4, pp. 89–93.

PANDEY, A. K., JAIN, A. K., and SINGH, D. P. 1991. An investigation into rock drilling, Int. J. Surface Min. Recl., 5, pp. 139–141.

PAONE, J. and MADSON, D. Drillability studies-impregnated diamond bits, US Bureau of Mines RI 6776, 1966, p.16.

PAONE, J., BRUCE, W.E., and VIRCIGLIO, P.R. Drillability studies—statistical regression analysis of diamond drilling, US Bureau of Mines RI 6880, 1966.

AUTHOR Adamson, Research Scholar, Department of Thermal Engineering, University of Nigde, Geological Engineering, Kampus, Nigde, Turkey.

Miller, Professor , Department of Thermal Engineering, University of Nigde, Geological Engineering, Kampus, Nigde, Turkey.

KAHRAMAN, S., BILGIN, N., and FERINDUNOGLU, C. Dominant rock properties affecting the penetration rate of percussive drills. Int. J. Rock Mech. Min. Sci., 2003, 40 (5), pp. 711–723.

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