MindMesh performed finite element analysis (FEA) to better understand the reamer performance when reamer drills through tortuous borehole. In this study, we compared borehole smoothness and reactive torque between two types of reamers (Figure 1). Our modeling process provided insight into reamer design and improved the reliability of reamer under downhole operating conditions.
In a collaborative project with MindMesh Inc. and Virtual Forming Inc., we developed virtual testing methods to Improve toe cap designs, (Fig. 1), for safety shoes. Toe caps are used in safety shoes by multiple industries so the toes of workers are not crushed during operations with heavy equipment. As part of this project, we formed toe caps that were lighter which met safety regulations.
To determine the limits for products undergoing erosion due to high flow rates, MindMesh Inc. performed several CFD analyses. These analyses were crucial in dealing with flow induced erosion which occurs daily in multiple industries, (Fig. 1). With this we were able to determine how erosion affects products, evaluate product design, and improve the overall reliability of products. Understanding the design, the flow characteristics, and materials of products allowed us to understand the design limits and provide insight to the clients.
MindMesh Inc. developed methods to better understand the behavior of mud motor performance under varying operating conditions through analytical and numerical methods. As part of this case study, we developed material calibration methods as discussed in case studies 2 and 3. Further, additional testing and calibration methods were developed to incorporate the effect of temperature variations and hysteresis. Through our modeling process, we improved the reliability of mud motors under downhole operating conditions.
To reduce the amount of water used for toilet flushing while still maintaining flushing efficiency is crucial for the next generation toilet. MindMesh Inc. developed multiphase Computational Fluid Dynamics (CFD) models to assist toilet design improvement. We used Tdyn, a state-of-the-art CFD software platform, to perform high-fidelity flushing flow analysis and Fluid-Structure Interaction (FSI) analysis. We designed various tests to improve the understanding of multiphase flow physics.
MindMesh Inc. took the knowledge gained from the 2D RCD Seal Case Study (case study #6), to aid in the investigation of RCD seals that are subject to operation variances that include drill pipe eccentricity, rotational speed, friction and external wellbore pressure. RCD seals often undergo deformation and eventual failure due to pressure differentials between the drill pipe and seal. Further drill pipe lateral vibrations or displacements can affect the performance of the seals and cause premature failures. Our role was to develop methods of the transient vibration behavior of the drill pipe and study the effects on the seal performance. This inturn helped the client to better understand the performance of the RCD seal, (Fig. 1) under actual operating condions.
Rotating Control Device (RCD) seals are devices used to control pressure during drilling. In order to gain a better insight of the RCD seal, MindMesh explored avenues to improve the seal design and expand our knowledge base of the seal. Used for both offshore and onshore drilling, this device makes a seal around the drill string while the drill string rotates and contains wellbore fluids under pressure (Fig. 1). The RCD seal prevents the release of these fluids while being used.
MindMesh Inc. took the knowledge gained in the model developed of pipe crushing (case study #4), to conduct 3D structural analysis of the Tubular Running Services, (TRS) spider to evaluate slips load limits and pipe crushing. With this, we studied the effect of slips engagement on the casing and the effect of axial loads on effectiveness of the slips. This analysis would also aid in investigating the effect of different friction coefficients and friction models and also determine the extent of pipe crushing to improve the understanding of premature pipe failures.
To understand and evaluate the indentation of dies and pipe crushing on casing for tubular service running operations (TRS), MindMesh developed a methodology to model the indentation process. The methods development was to aid one of the top tubular running services provider with better performance of their tools. A series of teeth-like grips called dies hold the casing in place, (Fig. 1), however these dies can leave permanent local deformations which over time may cause the pipes to fail prematurely.
MindMesh Inc. took the knowledge gained from the calibration of elastomers (refer to Hyperelastic Material Calibration Case Study), to aid in well testing tool development using nonlinear FEA Analysis. Material calibration for deformation and stress relaxation was developed which in turn was used for well testing tool development. The process of well testing is to understand the fluid qualities in the well and well performance so that the production of the well can be measured. Although well testing is done frequently, testing wells downhole accurately needs further improvement, hence, the need for further development of the well testing tool. In this case, the client primarily used a method of well testing called a drawdown test, when the well pressure is measured while the rate is kept constant. Our role was to improve upon the performance of the tool, (Fig. 1) used for drawdown tests that makes a significant pressure differential and in turn improves overall well efficiency.
To determine what the stress and strain limits are for elastomers, MindMesh Inc. performed several calibration tests for hyperelastic material models. This analysis was very crucial in calibrating rubber material which is used daily in multiple industries and by consumers worldwide. There were several types of tests used during this analysis. The tests include simple tension strain (Fig. 1), simple compression strain, equal biaxial strain (Fig. 2), pure shear strain (Fig. 3), and volumetric compression. With this we were able to understand how the material deforms, evaluate and calibrate material properties and utilize them for nonlinear FEA analysis (Fig. 4 and 5). Understanding material properties allows us to interpret the deformation and modes of failure for parts or components developed with rubber-like materials. There is a lot of research in this realm, however it is not yet mainstream and therefore the results need to be interpreted from an engineering perspective especially for damage and failure.
To increase casing efficiency and reliability, the requirement from a leading service provider was that MindMesh Inc. performed Collapse FEA analysis of the centralizer sub (shown in Fig. 1), under applied external pressure. This analysis was also to estimate the collapse pressure limit, and compare the collapse pressure limit predicted by API calculations. There were three designs used during this analysis. The designs included nominal material, minimum material and minimum material with ovality/offset conditions.
When we deal with any operator or whether we are talking to a directional Company or a downhole tool service provider, we give them the ability now to virtually test many changes in the hardware and in the operating parameters that now one would ever allow in the field simply because trail and error is too expensive. So now we give them the ability for the comparative analysis and sensitivity analysis and all the things to understand improvement while we’re still in the office in the engineering environment before we go to the operations at the rig where time is money and we’re able to affect improvement. Based upon the things we have learned through the software field.
MindMesh is the digital evolution of engineering. We
provide clients with sound technical expertise and
knowledge for products relating to design, manufacturing
process evaluations, and engineering of the product’s life
cycle. With over 15 years of industrial experience in diverse
disciplines, our team is uniquely equipped to resolve tough
and complicated engineering issues with success!