Numerical Simulation on Shale Fragmentation by a PDC Cutter Based on the Discrete Element Method

During the guided drilling process as part of shale gas exploration and development, shale is damaged by a polycrystalline diamond compact (PDC) bit cutter. It is essential to carry out research on rock breaking by a PDC cutter. In this paper, we study the mechanism of shale fragmentation by a PDC cutter based on the discrete element method. Additionally, we consider the effects of bedding angle, bedding thickness, cutting depth and cutting rate on the rock-breaking efficiency of a PDC cutter. The results show the following: (1) With the increase in bedding angle, the number and area of microcracks first increase and then decrease, and the proportion of tension cracks is relatively unchanged; there is no significant change in the morphology of the failure zone, and the average particle size of the cutting fragments first decreases and then increases. (2) With the increase in the bedding thickness, microcracks continue to extend in a horizontal direction, the total number of cracks shows a fluctuated change, and the proportion of tension cracks increases. The failure zone extends in a conical shape in the horizontal direction, and the average size of the cutting fragments gradually increases. (3) With the increase in cutting depth and cutting rate, the number and area of microcracks increase, and the proportion of shear cracks increases; the area of the failure zone increases and the size of the cutting fragment decreases.