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This thesis work is performed at Sandvik Mining Rock Tools, a world leading supplier of rock drilling tools. The work is part of developing a new tribological wear test method for cemented carbide drill bit inserts. The test method has earlier been judged successful in mimicking the rotary-percussive rock drilling process because it gives the same wear mechanisms as have been observed for inserts used in rock drilling. During testing the cemented carbide drill bit insert is pressed against a moving rock surface while water and particles are added to the contact area. The particles are present to simulate the rock crushings formed during drilling. They are believed to cause abrasive wear of the inserts. In this work the effect of load, particle material and particle size are studied. When adding silica particles, which are softer than the cemented carbide material, no correlation is obtained between wear rate and load or particle size. Cracking of WC grains, added rock material and removal of pieces of carbide material are seen at the worn sample surfaces. These observations are similar to observations described in other works about wear of cemented carbide. Adding alumina particles, which are harder than the sample material, gives high wear rate and ground/striped sample surfaces. The wear rate increases with alumina particle size.

<p>WC/Co cemented carbide is a composite material for highly demanding wear applications. The unique combination of hardness (from the WC-phase) and toughness (from the binder Co) gives a material especially suitable for rock drilling. This thesis, investigates the deterioration and wear of these cemented carbide buttons and the correlation to different rock types.</p><p>To better understand the nature of the wear of the cemented carbide buttons, the counter surface –the rock- has also been studied. A range of important rock types has been investigated with respect to hardness distribution and scratch response in a micro scale and friction properties when slid against cemented carbides. </p><p>The cemented carbide may deteriorate due to a number of mechanisms. The effect of fatigue in the structure was studied in TEM and particle erosion response was used to probe the corresponding mechanical degradation. </p><p>Further, homing cross sectioning has been developed and used as a new technique to investigate the presence of weak zones in the surface layer of a drill button. It was found that rock penetration into this layer is a very common mechanism, with profound implications for the nature of the wear. </p><p>High resolution scanning electron microscopy has been extensively used to map the deterioration and wear of numerous drill buttons, worn against different rock types in different kinds of drilling applications. Finally, the collected data on the surface damage, the reptile skin formation, the rock intrusion and the properties of the rock are assembled into a new view of the deterioration and wear of cemented carbide in rock drilling. </p>

WC/Co cemented carbide is a composite material for highly demanding wear applications. The unique combination of hardness (from the WC-phase) and toughness (from the binder Co) gives a material especially suitable for rock drilling. This thesis, investigates the deterioration and wear of these cemented carbide buttons and the correlation to different rock types. To better understand the nature of the wear of the cemented carbide buttons, the counter surface –the rock- has also been studied. A range of important rock types has been investigated with respect to hardness distribution and scratch response in a micro scale and friction properties when slid against cemented carbides. The cemented carbide may deteriorate due to a number of mechanisms. The effect of fatigue in the structure was studied in TEM and particle erosion response was used to probe the corresponding mechanical degradation. Further, homing cross sectioning has been developed and used as a new technique to investigate the presence of weak zones in the surface layer of a drill button. It was found that rock penetration into this layer is a very common mechanism, with profound implications for the nature of the wear. High resolution scanning electron microscopy has been extensively used to map the deterioration and wear of numerous drill buttons, worn against different rock types in different kinds of drilling applications. Finally, the collected data on the surface damage, the reptile skin formation, the rock intrusion and the properties of the rock are assembled into a new view of the deterioration and wear of cemented carbide in rock drilling.

This work has been performed at the Applied Materials ScienceDivision at The Ångström Laboratory in collaboration with SandvikMining AB. The project is part of the joint research programmeCoFree.In this work, the problem of finding an impact test method forcemented carbide rock drill inserts is considered. A suitable testmethod is required to benchmark alternative binder cemented carbidesagainst today’s cobalt based grades. The developed test method isbased on a Charpy pendulum arrangement and utilizes, as in rockdrilling, impact of cylindrical bars to achieve the high impact forcesufficient to fracture the rock drill inserts. The impact issymmetrical with two inserts facing each other, which proves to be anefficient way of damaging the inserts. To gain more informationregarding the force and pulse duration, the history of the impact isrecorded with the use of strain gauges. The measured force curvesfrom repeated tests are typically very similar, a strong indicationthat the test loads the buttons in a well-defined, repeatable way.Also, quasi-static loading of the insert is present in the impactwhich agrees to the results from a static compression test. Thisindicates that the inserts are subjected to quasi-static loading,rather than dynamic loading.A single impact test procedure was developed in this work. Thismethodology proved capable of differentiating the impact performanceof two different button cemented carbide grades. Hence, the test canbe used in the future as a benchmark test. It is however necessary toobtain statistical evidence. The impact performance was measured byobserving cracks produced in the impact contact zone with the aid ofan optical microscope with 85x objective. Radial cracks are veryoften found, often forming a cross around the contact zone. Whenlarge button chippings occur due to the impact loading, a very clearsudden drop in the measured force pulse is seen. This is however notseen for impacts that only produces cracks.

In this thesis, drill bit buttons with cobalt, nickel and iron binders in different compositions have been tested against granite and sandstone and the wear and friction have been measured. Furthermore, the wear and degradation of the buttons have been categorized. Buttons with cobalt binder were tested against granite and sandstone and buttons with alternative binders (Ni, Fe, Co) were tested against granite. Cobalt buttons were used as a reference and the wear and friction of the alternative binders was compared to the reference. The amount of worn rock was also measured. Furthermore, post treated drill bit buttons with a composition of Fe-Ni-Co were compared to buttons with the same composition that had not been post treated The results show that buttons with an alternative composition of Fe-Co-Ni and Fe- Ni wears less than the cobalt reference. The post treatment process does not decrease the wear of the drill bit but lowers the deviation from the mean wear. The amount of worn rock does not differ between the samples except for between the post treated and not post treated buttons with a composition of Fe-Ni-Co. The post treated buttons produces more rock debris than the not post treated. No apparent difference could be seen on the surface of the tested buttons after the test. However, composition specific cracks could be found underneath the surface of the samples. EDS-analysis showed signals of oxygen inside of all of the investigated cracks. For some compositions at depths of 20 micrometers. The curves of friction shows similar appearance but the values of the coefficient of friction differs. No apparent correlation was found between the wear and friction of the samples. Furthermore, no apparent correlation was found between the hardness and the wear of the buttons.

This thesis deals with the analysis of drilling technology of building materials and design of drilling tools. The thesis analyzes a given cutting materials and usability their applications for drilling of building materials. Further, the thesis deals with the creation of 3D model of drilling tool in SolidWorks environment and preparation of CNC program for cutting centre SP 208 SY which is controlled by Sinumerik system.

In a diffusion couple, the intimacy of the contact between the two parts is of high importance for the results. In a tribological contact, matter can transfer from one part to another and a very intimate contact is formed. A new method for investigating a tribological diffusion couple created in this way and consisting of rock and a cemented carbide (CC) drill bit button, is developed in this thesis. This is done as further studies of this couple can contribute to the understanding of drill bit wear in rock drilling. A complete experimental route, including sample preparation, tribological contact, heat treatment and analysis of samples, is presented. Heat treatment of samples was conducted both in an atmosphere of flowing argon and inside an evacuated and sealed quartz vacuum ampule. Heat treatment in flowing argon was rejected as an oxide formed on the sample surface.  Samples in quartz ampules were heat treated at either 1000 °C for 2 h or 21 h, or at 1100 °C for 2 h. Samples were repeatedly imaged with Scanning Electron Microscopy (SEM) and analysed with Energy Dispersive X-ray Spectroscopy (EDS) during the process. As Si and W have characteristic X-ray peaks in close proximity, the need for a detection method other than EDS to detect diffused Si in CC arose. Wavelength Dispersive X-ray Spectroscopy (WDS) performed well in that respect. Diffused Si could be found in the superficial Co pockets of the CC structure, by analysis with WDS.

While tribology involves the study of friction, wear, and lubrication of interacting surfaces, the tribosurfaces are the pair of surfaces in sliding contact with a fluid (or particulate) media between them. The ubiquitous nature of tribology is evident from the usage of its principles in all aspects of life, such as the friction promoting behavior of shoes on slippery water-lubricated walkways and tires on roadways to the wear of fingernails during filing or engine walls during operations. These tribosurface interfaces, due to the small length scales, are difficult to model for contact mechanics, fluid mechanics and particle dynamics, be it via theory, experiments or computations. Also, there is no simple constitutive law for a tribosurface with a particulate media. Thus, when trying to model such a tribosurface, there is a need to calibrate the particulate media against one or more property characterizing experiments. Such a calibrated media, which is the “virtual avatar” of the real particulate media, can then be used to provide predictions about its behavior in engineering applications. This thesis proposes and attempts to validate an approach that leverages experiments and modeling, which comprises of physics-based modeling and machine learning enabled surrogate modeling, to study particulate media in two key particle matrix industries: metal powder-bed additive manufacturing (in Part II), and energy resource rock drilling (in Part III). The physics-based modeling framework developed in this thesis is called the Particle-Surface Tribology Analysis Code (P-STAC) and has the physics of particle dynamics, fluid mechanics and particle-fluid-structure interaction. The Computational Particle Dynamics (CPD) is solved by using the industry standard Discrete Element Method (DEM) and the Computational Fluid Dynamics (CFD) is solved by using finite difference discretization scheme based on Chorin's projection method and staggered grids. Particle-structure interactions are accounted for by using a state-of-the art Particle Tessellated Surface Interaction Scheme and the fluid-structure interaction is accounted for by using the Immersed Boundary Method (IBM). Surrogate modeling is carried out using back propagation neural network. The tribosurface interactions encountered during the spreading step of the powder-bed additive manufacturing (AM) process which involve a sliding spreader (rolling and sliding for a roller) and particulate media consisting of metal AM powder, have been studied in Part II. To understand the constitutive behavior of metal AM powders, detailed rheometry experiments have been conducted in Chapter 5. CPD module of P-STAC is used to simulate the rheometry of an industry grade AM powder (100-250microns Ti-6Al-4V), to determine a calibrated virtual avatar of the real AM powder (Chapter 6). This monodispersed virtual avatar is used to perform virtual spreading on smooth and rough substrates in Chapter 7. The effect of polydispersity in DEM modeling is studied in Chapter 8. A polydispersed virtual avatar of the aforementioned AM powder has been observed to provide better validation against single layer spreading experiments than the monodispersed virtual avatar. This experimentally validated polydispersed virtual avatar has been used to perform a battery of spreading simulations covering the range of spreader speeds. Then a machine learning enabled surrogate model, using back propagation neural network, has been trained to study the spreading results generated by P-STAC and provide much more data by performing regression. This surrogate model is used to generate spreading process maps linking the 3D printer inputs of spreader speeds to spread layer properties of roughness and porosity. Such maps (Chapters 7 and 8) can be used by a 3D-printer technician to determine the spreader speed setting which corresponds to the desired spread layer properties and has the maximum spread throughout. The tribosurface interactions encountered during the drilling of energy resource rocks which involve a rotary and impacting contact of the drill bit with the rock formation in the presence of drilling fluids have been studied in Part III. This problem involves sliding surfaces with fluid (drilling mud) and particulate media (intact and drilled rock particles). Again, like the AM powder, the particulate media, viz. the rock formation being drilled into, does not have a simple and a well-defined constitutive law. An index test detailed in ASTM D 5731 can be used as a characterization test while trying to model a rock using bonded particle DEM. A model to generate weak concrete-like virtual rock which can be considered to be a mathematical representation of a sandstone has been introduced in Chapter 10. Benchtop drilling experiments have been carried out on two sandstones (Castlegate sandstone from the energy rich state of Texas and Crab Orchard sandstone from Tennessee) in Chapter 11. Virtual drilling has been carried out on the aforementioned weak concrete-like virtual rock. The rate of penetration (RoP) of the drill bit has been found to be directly proportional to the weight on bit (WoB). The drilling in dry conditions resulted in a higher RoP than the one which involved the use of water as the drilling fluid. P-SATC with the bonded DEM and CFD modules was able to predict both these findings but only qualitatively (Chapter 11)

[pt] Neste estudo é apresentada a análise da interação da luz laser de alta potência com rochas nos processos de perfuração por fragmentação térmica. O objetivo principal do trabalho é estabelecer, através de um estudo experimental, a possibilidade de utilizar a tecnologia a laser na perfuração de rochas duras, tais como o granito, quartzo, entre outros. Sua motivação encontra-se na aplicação de novas tecnologias para desenvolver ferramentas que melhorem a eficiência no processo de perfuração de poços (maior taxa de penetração), e conseguir retirar a maior quantidade de material fragilizado pela irradiação do laser. Para isto, foi necessário fazer uma montagem opto–mecânica envolvendo um sistema de limpeza que ajudasse a remover o material fragilizado pela ação do laser, usando-se gás de nitrogênio a alta pressão. Foram analisados diferentes intervalos de tempo de exposição da radiação do laser nas rochas, para avaliar a taxa de volume retirado, e a quantidade de energia específica requerida para perfurar diferentes materiais, em função da potência e do tempo de irradiação do laser. Seguindo a revisão bibliográfica na seleção do material, foram escolhidos três tipos de materiais (granito branco, granito cinza e travertino) conhecidos comercialmente no Brasil e que têm similitude (na composição química) com as rochas encontradas nas formações do Pré-sal. A partir desta seleção, foi indispensável conhecer a composição química dos materiais através de fluorescência, raios X, e Microscopia de Varredura (MEV). Além disso, estudou-se o comportamento termomecânico das rochas carbonáticas através de análises térmicas (Termogravimetria e Análise Térmico Diferencial), para identificar e compreender os fenômenos envolvidos no processo de perfuração. Os resultados obtidos são analisados para parametrizar as variáveis em consideração, melhorando as condições do processo de perfuração por fragmentação térmica, dependendo do material estudado. / [en] This study presents the analysis of the interaction of high power laser light with rocks in thermal fragmentation drilling processes. The main objective of the work is to establish, through an experimental study, the possibility of using laser technology in the drilling of hard rocks, such as granite, quartz and others. The motivation is the application of new technologies to develop tools that improve the efficiency in the well drilling process (higher penetration rate), and to be able to remove the largest amount of material weakened by laser irradiation. For this, it was necessary to make an opto-mechanical assembly involving a cleaning system that would help to remove the material weakened by the action of the laser, using nitrogen gas at high pressure. Different exposure time intervals of laser radiation in the rocks were analyzed to evaluate the volume rate removed and the amount of specific energy required to drill different materials, depending on the power and irradiation time of the laser. Following the literature review in selecting the material, three types of materials (white granite, gray granite and travertine) known commercially in Brazil and that are similar (in chemical composition) to the rocks found in the pre-salt formations were chosen. From this selection, it was essential to know the chemical composition of the materials through fluorescence, X-rays, and Scanning Microscopy (SEM). In addition, the thermomechanical behavior of the carbonate rocks wasstudied through thermal analysis (Thermogravimetry and Differential Thermal Analysis) to identify and understand the phenomena involved in the drilling process. The results obtained are analyzed to parameterize the variables under consideration, improving the conditions of the drilling process by thermal fragmentation, depending on the material studied.