Development of a six-cone drill bit for efficient drilling of hard and ultra-hard rocks through optimised borehole bottom configuration

Serhii Minieiev Oleksandr Pashchenko Volodymyr Antonchyk Valentyn Hankevych Viacheslav Kiba
Received 07.06.2025, Revised 20.11.2025, Accepted 24.12.2025
Abstract

This study addressed the challenge of efficient drilling of hard and ultra-hard rock formations, characterised by high energy consumption, significant wear of drilling tools, and low penetration rates. The objective was to develop a drilling technology aimed at optimising rock destruction by creating a specialised borehole bottom configuration to facilitate effective rock shearing through tangential stresses. The methodology involved analysing rock failure mechanisms, mathematical modelling of the rock’s stress-strain state using ANSYS software, and experimental testing on granite and basalt samples with compressive strengths of 150-200 MPa. A six-cone drill bit was designed, incorporating separate cone wheels for creating a leading annular cut in the borehole’s peripheral zone, main cones for staged rock shearing, and core cones for breaking the central part of the borehole bottom, preventing core formation and tool damage. Experimental results demonstrated that the proposed technology enables the destruction of approximately 80% of the borehole bottom surface through tangential stresses, reducing energy consumption by 1.4-1.7 times compared to conventional roller-cone drilling methods, as confirmed by energy consumption measurements. The drilling rate increased by 1.2-1.5 times, as validated by field tests. Laboratory measurements indicated that the bearing rollers withstand an average load of 1,000 kg per centimetre of bit diameter, with peak loads from bottom reaction, recorded by dynamometric equipment, exceeding operational loads by 3-4 times. The bearing cooling system, utilising water emulsion and compressed air, reduced bearing temperatures from 200-300°C in conventional designs to 80-100°C, as evidenced by thermal imaging, extending bit lifespan by 1.7-2 times. Statistical analysis with a 95% confidence interval confirmed consistent performance, with an average error of ±0.2 m/h for drilling rate and ±0.5 kW·h/m for energy consumption. The technology reduces wear on teeth and bearings, extending tool life by 2.7-3 times. These findings enable broad application in the mining industry, particularly in challenging geological conditions, enhancing drilling efficiency and reducing costs

Keywords:
drill bit; roller cone; borehole bottom; shear stress; kerf cutting

Retrieved from Vol. 59, No. 2, 2025

Pages 46–55

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Minieiev, S., Pashchenko, O., Antonchyk, V., Hankevych, V., & Kiba, V. (2025). Development of a six-cone drill bit for efficient drilling of hard and ultra-hard rocks through optimised borehole bottom configuration. Mining Journal of Kryvyi Rih National University, 59(2), 46-55. https://doi.org/10.31721/2306-5435-2025-2-46-55
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