Frangible Slip with Hard Inserts for Downhole Tool Engagement
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Solution Overview
Problem
Existing slip members for securing downhole tools in wellbores face challenges in efficiently engaging with the wellbore surface due to the hardness difference between the tool materials, making manufacturing and deployment cumbersome.
Innovation Solution
The design incorporates hard material elements aligned at various angles through a softer body material, allowing for a gripping surface on either side and different cross-sectional shapes, facilitating easier manufacturing and engagement with the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard material elements are used for the gripping surface, then the gripping strength and reliability are improved, but the manufacturing difficulty and device complexity increase
Solution Approach 1:
The slip member combines hard material elements (such as carbide or ceramic inserts) with a softer body material (such as polymer or metal) to create a composite structure. The hard elements provide the gripping strength and wear resistance, while the softer body material allows for easier manufacturing through processes like injection molding or machining. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The slip member is divided into distinct segments: the hard material elements and the softer body material. The hard elements can be inserted as separate components into the body material during manufacturing. This segmentation allows each material to be optimized independently - the hard elements for gripping performance and the soft body material for manufacturing ease - thereby resolving the contradiction between reliability and ease of manufacture.
2Strength
If hard material elements are used throughout the slip member, then the strength and durability are improved, but the ease of removal and operational efficiency deteriorate
Solution Approach 1:
The hard material elements are strategically positioned only in specific locations where gripping strength is needed, such as on the gripping surface or at contact points with the wellbore. The softer body material is used in regions where ease of removal or operational flexibility is prioritized. This local differentiation allows the slip member to maintain durability where required while enabling easy removal where needed, resolving the contradiction between strength and ease of operation.
3Ease of manufacture
If the slip member is made entirely from soft material, then the ease of manufacture and removal are improved, but the gripping capability and reliability deteriorate
Solution Approach 1:
The slip member uses a composite construction where the softer body material (easier to mill) serves as the base structure, while hard material elements are embedded within it to provide the necessary gripping capability. This allows the majority of the component to be manufactured from soft, easily worked material, while the hard elements compensate for any deficiency in gripping strength, thus resolving the contradiction between ease of manufacture and reliability.
4Reliability
If hard material elements are positioned at specific angles, then the gripping effectiveness is improved, but the manufacturing complexity increases
Solution Approach 1:
The hard material elements are pre-positioned at specific angles during the manufacturing process, such as during injection molding or assembly operations. This preliminary positioning ensures that the gripping surfaces are oriented correctly for maximum effectiveness when the slip member is deployed. By incorporating the angular positioning into the manufacturing process itself, the complexity is managed more efficiently, resolving the contradiction between gripping effectiveness and manufacturing complexity.
Data Source
AI summary
Slip members for use with downhole tools comprise a body formed of a first or body material and one or more hard material elements formed of a second or element material. The element material is harder than the body material. The hard material element is disposed through the body and in communication with a first surface and a second surface of the body, the second surface being disposed opposing the first surface. During manufacturing of the slip members, the hard material element may extend outwardly from one or both of the first and second surfaces. After manufacturing, the hard material element can be shaped to provide a gripping member.