CN105649538B - 栅格状工作层金刚石钻头及其3d打印制作工艺 - Google Patents
栅格状工作层金刚石钻头及其3d打印制作工艺 Download PDFInfo
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Abstract
一种栅格状工作层金刚石钻头及其3D打印制作工艺，本发明栅格状工作层是由实体与空隙体沿径向与周向分布构成，栅格状工作层与非工作层、钻头钢体共同构成钻头整体。在非工作层胎体唇面利用激光烧结工艺3D打印栅格状工作层。本发明减小了工作层与岩体的接触面积，增大钻压，增加磨粒的出刃进而提高磨削效率，优化坚硬、极硬地层岩石的金刚石钻头破碎方法，与岩石接触面上除存在弹性接触、塑性接触外，还存在着强切削机械作用,大大地提高了钻进效率。本发明采用智能化的3D打印制作技术，利于改进、弥补传统钻头制造中的不足，方便实现复杂异形工作面钻头的制造，提高生产效率。
Description
技术领域
本发明属于机械加工和钻探工程领域，尤其涉及钻进过程中使用的栅格状工作层金刚石钻头及采用3D打印的加工制作工艺。
背景技术
智能3D打印技术，无需制作模具，不仅可得到复杂的异形结构产品，且生产速度快、精度高。传统制造钻头是依靠粉末冶金法或电镀法等来完成的，工作层唇面结构难以制造为各种利于破碎岩石的复杂形状，钻进中如果遇到极端地层岩石或复杂情况，导致钻头钻进效率低下或钻头寿命较短，大幅度增加施工成本，影响了钻探技术水平的提高和发展。
发明内容
本发明的目的是提供一种栅格状工作层金刚石钻头及其3D打印制作工艺。
本发明栅格状工作层金刚石钻头包括栅格状工作层、非工作层和钻头钢体三部分，栅格状工作层是由实体与空隙沿径向与周向分布构成，栅格状工作层中，沿径向的实体厚度为0.05～1.0mm，空隙体厚度0.05～0.30mm；栅格状工作层中，沿周向的实体厚度为0.05～1.0mm，空隙体厚度0.05～0.30mm；栅格状工作层内径外侧、外径内侧的实体厚度比中间栅格部位的实体厚度宽0.05～0.5mm；栅格状工作层孕镶块靠近水口方向两端，实体厚度比中间栅格的实体厚度宽0.05～0.5mm；栅格状工作层与非工作层、钻头钢体共同构成钻头整体。
所述的栅格状工作层金刚石钻头，其非工作层的材料含单晶金刚石、聚晶金刚石或硬质合金保径材料。
栅格状工作层金刚石钻头的制作工艺流程为：第一步：钢体和模具机械加工；第二步：非工作层胎体粉末混合；第三步：粉末冶金热压法制造含单晶金刚石或聚晶金刚石或硬质合金保径材料的非工作层；第四步：冷却脱模；第五步：丝扣机械加工；第六步：修整抛磨非工作层唇面；第七步：工作层胎体粉末和金刚石混合；第八步：在非工作层胎体唇面利用激光烧结工艺3D打印栅格状工作层；具体过程为：
先将激光烧结过程中的相关参数输入到计算机控制系统中，其中，激光功率为200～500W，扫描速率0.01～0.06m/s，粉层厚度0.02～0.50mm；再铺粉滚筒将供粉缸中的工作层胎体粉末均匀地铺放于成形缸中的基板上，将胎体粉末铺设成厚度为0.02～0.50mm的粉层，激光束根据计算机中的数据信息烧结粉层，完成第一个层面的烧结；然后成形缸活塞下降0.02～0.50mm，供粉缸活塞上升0.02～0.50mm，铺粉滚筒再次将粉末铺平，激光束依照计算机中的数据信息烧结第二层；重复上述工艺步骤，直至栅格状工作层完成，金刚石钻头制造完毕。
所述的步骤二中非工作层胎体粉末的配方是：非工作层中胎体含钴粉、镍粉、铁粉、钛粉、铬粉、铜粉、锡粉、碳化钨和碳化二钨，其中：钴粉、镍粉、铁粉、钛粉和铬粉粉末质量各占总质量的4％～70％；铜粉和锡粉粉末质量各占总质量的8％～50％；碳化钨和碳化二钨粉末质量占总质量的30％～60％；所用非工作层中胎体粉末颗粒直径为0.05～0.25mm。
所述的步骤八中工作层胎体粉末配方为：含钴粉、镍粉、铁粉、钛粉、铬粉、钼粉、铜粉、钨粉、碳化钨和金刚石粉末，其中：钴粉、镍粉、铁粉、钛粉、铬粉和钼粉粉末质量占总质量的3％～70％；铜粉粉末质量占2％～50％；钨粉和碳化钨粉末质量占20％～80％；工作层胎体粉末颗粒直径为0.05～0.25mm，金刚石粉末的体积浓度在5％～60％之间，颗粒度为0.05～0.25mm。
本发明栅格状工作层金刚石钻头，与传统钻头相比，减小了工作层与岩体的接触面积，增大钻压，增加磨粒的出刃进而提高磨削效率，优化坚硬、极硬地层岩石的金刚石钻头破碎方法和机理，与岩石接触面上除存在弹性接触、塑性接触外，还存在着强切削机械作用,大大地提高了钻进效率；可以增大冲洗液与工作层胎体的接触面积，使得工作层胎体冷却充分，大大延长了钻头使用寿命。本发明采用智能化的3D打印制作技术，利于改进、弥补传统钻头制造中的不足，方便实现复杂异形工作面钻头的制造，提高生产效率。
附图说明：
图1是本发明立体示意图；
图2是本发明孕镶块的示意图；
图3是本发明唇面示意图。
具体实施方式：
实施例1
如图1、2、3所示，栅格状工作层1、非工作层2和钻头钢体3三部分，栅格状工作层1是由工作层实体4与工作层空隙体5沿径向与周向分布构成，栅格状工作层中，沿径向的实体厚度为0.08mm，空隙体厚度0.1mm；栅格状工作层中，沿周向的实体厚度为0.08mm，空隙体厚度0.1mm；栅格状工作层内径外侧、外径内侧的实体厚度比中间栅格部位的实体厚度宽0.3mm；栅格状工作层孕镶块7靠近水口6方向两端，实体厚度比中间栅格部位的实体厚度宽0.3mm；栅格状工作层与非工作层、钻头钢体共同构成钻头整体。
其制作工艺流程为：
①钢体和模具机械加工。
②非工作层胎体粉末混料。
③粉末冶金热压法制造含单晶金刚石或聚晶金刚石或硬质合金等保径材料的非工作层，钻头钢体通过本工艺方法牢固地烧结压制在非工作层端部。
④冷却脱模。
⑤利用机加工技术，加工好钻头钢体部分的丝扣等。
⑥修整抛磨非工作层唇面。
⑦工作层胎体粉末和金刚石混合。
⑧在洁净的非工作层唇面利用激光烧结等工艺3D打印栅格状工作层。
首先，3D打印设备的电脑数控系统中设计的栅格状工作层金刚石钻头形状和尺寸如下：
栅格状工作层中，沿径向的实体厚度为0.08mm，空隙体厚度0.1mm；栅格状工作层中，沿周向的实体厚度为0.08mm，空隙体厚度0.1mm；栅格状工作层内径外侧、外径内侧的实体厚度比中间栅格部位的实体厚度宽0.3mm；栅格状工作层孕镶块靠近水口方向两端，实体厚度比中间栅格部位的实体厚度宽0.3mm。
然后，将激光烧结过程中的相关参数输入到计算机控制系统中，其中，激光功率为200W，扫描速率为0.02m/s，粉层厚度为0.05mm。接着，铺粉滚筒将供粉缸中的工作层胎体粉末(含金刚石)均匀地铺放于成形缸中的基板上，将其铺设成0.05mm的粉层，激光束根据计算机中的数据信息烧结粉层，完成第一个层面的烧结；然后成形缸活塞下降0.05mm，供粉缸活塞上升0.05mm，铺粉滚筒再次将粉末铺平，激光束依照计算机中的数据信息烧结第二层；重复上述工艺步骤，直至栅格状工作层完成，金刚石钻头制造完毕。
Claims (5)
1.一种栅格状工作层金刚石钻头，其特征在于：包括栅格状工作层、非工作层和钻头钢体三部分，栅格状工作层是由实体与空隙沿径向与周向分布构成，栅格状工作层中，沿径向的实体厚度为0.05～1.0mm，空隙体厚度0.05～0.30mm；沿周向的实体厚度为0.05～1.0mm，空隙体厚度0.05～0.30mm；栅格状工作层内径外侧、外径内侧的实体厚度比中间栅格的实体厚度宽0.05～0.50mm；栅格状工作层孕镶块靠近水口方向两端，实体厚度比中间栅格的实体厚度宽0.05～0.50mm；栅格状工作层与非工作层、钻头钢体共同构成钻头整体。
2.根据权利要求1所述的栅格状工作层金刚石钻头，其特征在于：所述的非工作层的材料含单晶金刚石、聚晶金刚石或硬质合金保径材料。
3.根据权利要求1所述的栅格状工作层金刚石钻头的3D打印制作工艺，其特征在于：
第一步：钢体和模具机械加工；第二步：非工作层胎体粉末混合；第三步：粉末冶金热压法制造含单晶金刚石或聚晶金刚石或硬质合金保径材料的非工作层；第四步：冷却脱模；第五步：丝扣机械加工；第六步：修整抛磨非工作层唇面；第七步：工作层胎体粉末和金刚石混合；第八步：在非工作层胎体唇面利用激光烧结工艺3D打印栅格状工作层，具体过程为：
先将激光烧结过程中的相关参数输入到计算机控制系统中，其中，激光功率为200～500W，扫描速率0.01～0.06m/s，粉层厚度0.02～0.50mm；再铺粉滚筒将供粉缸中的工作层胎体粉末均匀地铺放于成形缸中的基板上，将胎体粉末铺设成厚度为0.02～0.50mm的粉层，激光束根据计算机中的数据信息烧结粉层，完成第一个层面的烧结；然后成形缸活塞下降0.02～0.50mm，供粉缸活塞上升0.02～0.50mm，铺粉滚筒再次将粉末铺平，激光束依照计算机中的数据信息烧结第二层；重复上述工艺步骤，直至栅格状工作层完成，金刚石钻头制造完毕。
4.根据权利要求3所述的栅格状工作层金刚石钻头3D打印制作工艺，其特征在于：
步骤二中非工作层胎体粉末的配方是：非工作层中胎体含钴粉、镍粉、铁粉、钛粉、铬粉、铜粉、锡粉、碳化钨和碳化二钨，其中：钴粉、镍粉、铁粉、钛粉和铬粉粉末质量各占总质量的4％～70％；铜粉和锡粉粉末质量各占总质量的8％～50％；碳化钨和碳化二钨粉末质量占总质量的30％～60％；所用非工作层中胎体粉末颗粒直径为0.05～0.25mm。
5.根据权利要求3所述的栅格状工作层金刚石钻头3D打印制作工艺，其特征在于：步骤八中工作层胎体粉末配方为：含钴粉、镍粉、铁粉、钛粉、铬粉、钼粉、铜粉、钨粉、碳化钨和金刚石粉末，其中：钴粉、镍粉、铁粉、钛粉、铬粉和钼粉粉末质量占总质量的3％～70％；铜粉粉末质量占2％～50％；钨粉和碳化钨粉末质量占20％～80％；工作层胎体粉末颗粒直径为0.05～0.25mm，金刚石粉末的体积浓度在5％～60％之间，颗粒度为0.05～0.25mm。
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