PSI - Issue 83

Iman Onsa et al. / Procedia Structural Integrity 83 (2026) 273–279

279

4. Discussion The results suggest that casing wear in L-80 steel is influenced primarily by the interaction of normal load and lubrication conditions. Side-load increases the contact pressure applied to the casing and therefore increases the wear driving term in Archard-type formulations. The lubrication condition modifies how the casing responds to friction; therefore, by increasing the friction coefficient in the system, there will be greater tangential traction and energy dissipated through sliding friction, which creates a greater predicted wear for WBM versus OBM under the same load and speed. The increase in separation between OBM and WBM at higher loads demonstrates that the lubrication strategy has become increasingly important in the higher side-load regions, such as highly deviated sections or regions with high dogleg severity. The modelling approach uses constant values for friction coefficients and calibrated wear coefficients. This is appropriate for comparative evaluation but may not fully encompass all the field-dependent effects on casing wear (i.e. temperature, cuttings abrasivity, mud chemistry, and time-varying contact). However, since all other parameters except for lubrication condition were held constant for WBM and OBM, the differences in wear observed are due to the different friction behaviours of the two different lubrication conditions and not due to variations in casing geometry or loadings. 5. Conclusion • A finite element wear model was developed in ANSYS Workbench LS-DYNA using Archard's wear law as a basis to evaluate casing wear due to a hardened steel tool joint in API 5CT L-80. • Results indicated a positive relationship between wear depth and wear volume in response to an increase in the inside load between 1000 and 1400 N. The maximum side load is a primary factor influencing casing wear within the scope of the study. • WBM generated more casing wear than OBM under identical operating conditions, due to its higher friction coefficient and greater frictional force at the casing outputs. • The distinction between WBM and OBM was greater under high side loads, demonstrating the importance of selecting the proper lubricant during periods of high contact severity. • The FE model that has been validated/calibrated serves as a low-cost option for determining the effects of changing mud types or any operational parameters on the amount of casing wear. [1] Y. Liu et al. , “Integrated Casing Wear Management in Well Design and Drilling Operations with a Field Case Analysis,” APOGCE 2024 , 2024, doi: 10.2118/221231-ms. [2] H. Patel, S. Baldino, and E. Ozbayoglu, “Enhanced Casing Wear Assessment: A New Experimental Approach to Wear Factor Evaluation with Insights into Flow Regimes, Tool-Joint Materials, and Presence of Cuttings,” SPE J. , 2025, doi: 10.2118/228282-pa. [3] Y. Fouad et al. , “Tribological Characterization of a Novel Ceramic–Epoxy–Kevlar Composite,” Polymers (Basel). , vol. 16, 2024, doi: 10.3390/polym16060785. [4] O. Osman, N. Merah, M. Abdul Samad, A. Al-Shaarawi, and M. Alshalan, “Effects of Drilling Parameters and Mud Types on Wear Factors and Mechanisms of SM2535 Casings,” Lubricants , vol. 11, no. 10, pp. 1–15, 2023, doi: 10.3390/lubricants11100420. [5] O. A. Osman et al. , “Casing Wear and Wear Factors: New Experimental Study and Analysis.,” Mater. (Basel, Switzerland) , vol. 15, no. 19, Sep. 2022, doi: 10.3390/ma15196544. [6] S. Irawan, A. M. Bharadwaj, B. Temesgen, S. Karuppanan, and M. Z. B. Abdullah, “Effect of wear on the burst strength of l-80 steel casing,” IOP Conf. Ser. Mater. Sci. Eng. , vol. 100, no. 1, 2015, doi: 10.1088/1757-899X/100/1/012027. [7] P. W. McMullin, Mechanics of materials . 2016. doi: 10.4324/9781315737737-17. [8] O. A. Osman et al. , “Wear factors and mechanisms of L-80 steel casings,” Eng. Res. Express , vol. 5, 2023, [Online]. Available: https://api.semanticscholar.org/CorpusID:259258350 References