Numerical simulation and experimental study of hole cleaning

Insufficient hole cleaning causes tool wear and reduces drilling efficiency. Existing evaluation methods and models are limited. In this study, a universal method is proposed to assess hole cleaning efficiency (HCE). A coupled computational fluid dynamics and discrete element method (CFD-DEM) numerical model for non-Newtonian fluid simulation of cuttings transport is developed. The influence of various factors on HCE was analyzed from an energy and particle collision perspective, with a particular focus on the mechanisms of fluid viscosity and rate of penetration (ROP) on cuttings settling. Results show that increased fluid viscosity improves HCE, while excessive viscosity negatively affects it. Higher ROP results in increased solid particle concentration and collision probability, leading to energy loss and reduced efficiency. Lower HCE was observed when the inclination deviated from the vertical. The HCE can be significantly improved by increasing the fluid velocity and reducing the eccentricity. A comprehensive prediction model for HCE is established using Design of Experiment (DOE), dimensional analysis, and nonlinear regression. This model incorporates a generalized fluid apparent viscosity, taking into account the impact of each rheological parameter. Additionally, it can be applied to predict hole cleanliness in both Newtonian and non-Newtonian fluids. By comparing the experimental results of hole cleanliness in three distinct fluids, the regression model yielded reliable predictive results. The findings enhance understanding regarding how fluid properties and the ROP affect cuttings transport and enable precise and convenient prediction and optimization of hole cleaning efficiency. © 2024 Elsevier Ltd