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2008 GT 01 Drilling PPL
2008 GT 01 Drilling PPL
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Ralf J. Plinninger
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Ralf J. Plinninger
Abstract: The wear of drilling tools in mining and tunnelling has always been a predominant
factor for the costs of hardrock excavation. This fact is not only related to material and person-
nel costs arising from drill bit maintenance and replacement but also because of the direct and
negative impact of wear on the drilling performance of a worn drill bit. The first chapter presents
machinery, tools and basic findings on wear and performance interactions as well as drilling tool
wear mechanisms. Based on this theoretical background, methods and classifications for on-
site investigation of encountered tool wear rate and wear types are presented. The paper then
summarises laboratory approaches for assessing of rock abrasivity in order to predict drilling
tool wear from geotechnical investigations.
Keywords: Drilling, Tool Wear, Wear Classification, Wear Prediction, Rock Abrasivity
Underground small diameter tophammer drilling (usually 38-65 mm) for drill-and-blast-
tunnelling and small diameter rock support measures (rockbolts and anchors),
Surface or underground larger diameter tophammer drilling (usually 65-100 mm) for
mining or underground bench excavation,
Surface or underground larger diameter down-the-hole (DTH) drilling (usually > 100
mm) for blasthole drilling, installation of anchors or exploration of geothermal energy.
All methods presented are rotary percussive drilling methods. Nevertheless the different appli-
cations have lead to a variety of specialised machinery and tools used and these differences
include for instance the use of hydraulic or pneumatic energy transmission, tophammer or DTH
equipment and drill tools of different diameter and layout (Figure 1).
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 1: Typical layouts of drilling equipment: Tunnelling boomer (Type: Rocket Boomer L2C drill), DTH
Anchor drilling rig (Type: DIAMEC U6) and surface mining drill rig (Type: ROC D7; based on Atlas Copco
drawing and photos)
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Primarily button bits are used today for all of the mentioned equipment. Due to their effective-
ness and aggressiveness this bit layout has since the 1950s replaced older tool layouts like bits
with cross- or X-shaped bars of steel or hard metal (which however still exist). Button bits con-
sist of a number of cemented carbide buttons (mostly tungsten carbide in a cobalt binder),
inserted and/or soldered into holes of a steel tool body (Figure 2). The properties of the bit can
be adjusted effectively to the machinery and overall geological circumstances by varying the
number of inserted buttons, button composition, button geometry, soldering and steel quality as
well as the bit's flushing layout.
For the investigation of tool wear processes, it is crucially important to understand rock fragmen-
tation under the bits. As this magazine issue features some of the latest research results on this
topic (see paper by Thuro & Schormair, also [8], [13]), the description of these processes is not
part of this paper. Nevertheless it should be mentioned that the findings and schemes present-
ed in this paper relate only to the commonly used button bit types and the specific rock
fragmentation processes occurring with these bits.
Figure 3: Schemes for the influence of button shape on rock penetration for ballistic (left), spherical (cen-
tre) and worn (right) buttons.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 4: Schemes for the advancing decrease of penetration rate and the increasing probability of button
damage with continuing button wear flat (acc. to ATLAS-COPCO diagrams).
Additionally wear will of course also affect other tool parts such as for example the flushing
holes and flushing flutes. It is an astonishing finding that the widening of the flushing system in
the course of tool wear and the better flushing capabilities of such worn bits have in some cases
shown even better drilling performances than new ones – especially in soft rock formations,
where the flushing of the rock debris may be a limiting factor to drilling velocity [8].
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 5: The three fields Geology-Tools-Logistics as the main factors influencing button bit wear.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 6: Relation of abrasive wear rate and the ratio of hardness between the interacting materials.
Following these considerations, minerals of a Mohs hardness of more than 51/2 can be classified
as "abrasive" (causing high level abrasive wear) against the steel tool body, minerals with a
Mohs hardness of more than 9 are "abrasive" against tool body and hard metal buttons. Alt-
hough "abrasive" minerals with respect to cemented carbides exist (e.g. corundum, diamond),
they rarely occur naturally. The fact that cemented carbides normally also undergo (low level)
abrasive wear can be explained by microcracking processes and "erosion" of the softer cobalt
binder and consequently removal of whole carbide grains out of the button surface.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Additional
No. Description of Method Method Error
expenses
Documentation of drill period/drilled meters for a
M1 rather high approx. 1 %
single marked tool
Stock documentation: Documentation of
M2 low approx. 2 %
date/number of incoming and outgoing tools
M3 Calculations based on receipts and invoices very low approx. 5-10 %
Table 2 gives an example for terms to describe button bit wear rate and drill bit lifetime for but-
ton bits 43 - 48 mm according to [14]. As bits of larger diameter will under the same
circumstances achieve higher bit lifetimes (see Figure 10 for example) it should be noted that
these terms have to be adapted if bits of diameters other than 43-48 mm are used.
Table 2: Bit wear rate classification for button bits 43 - 48 mm [14].
wear rate drill bit lifetime [m/bit] drill bit lifetime
term term
very low > 2000 very high
low 1500-2000 high
moderate 1000-1500 moderate
high 500-1000 low
very high 200-500 very low
extremely high < 200 extremely low
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 7: Tool wear type documentation on site. 40 pieces of worn 89 mm button bits. lined up for docu-
mentation and classification.
Based on classification schemes developed during the 1990s (e.g. [14]) an easy-to-use classifi-
cation system for button bits and their main wear forms according to [8] is presented in Figure 8.
It is evident that transitions and mixed types between the presented types are possible.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
mainly the hard metal inserts are in contact with the rock and are therefore worn with low wear
rates - even by minerals that can be classified as "non abrasive" to cemented carbides. The
steel body is worn at high wear rate when directly exposed to the rock due to wearing of the
buttons.
Predominant wear of the tool body (BB-A2) with possible breaking out of buttons (BB-A3) is a
typical phenomenon for drilling weak but abrasive rock types. It can often be observed in poorly
cemented or weathered sandstone, sandy marlstone or weathered granite or gneiss. In these
rock types the bit penetrates deep into the rock mass and produces a large flow of rock debris,
so that both steel body and buttons are more or less evenly exposed to abrasive material. Since
steel and cemented carbide undergo different wear rates while in contact with the same coun-
terparts, the tool body wears faster than the inserted buttons and the buttons are created out of
their steel bedding. When embedding is insufficient they may fall out or are easily broken out of
the bit as a whole (BB-A3). If one button is broken out, this may also affect other buttons, be-
cause the broken out hard metal button is hardly removed from the hole.
Wear of diameter (BB-A4, BB-A5) is often found in extremely hard and highly abrasive quartz-
ites as well as under unstable or highly stressed abrasive rock conditions. First, the peripheral
buttons begin to show wear on the outer side (BB-A4), later the tool body itself is affected, the
hole diameter of the bit is reduced and peripheral buttons break out (BB-A5).
If macroscopic failure of buttons (BB-F1, BB-F2) prevails, this normally is in conjunction with
high tool wear rates. In most cases this failure type is more related to properties of the rock
mass, machinery and tools than to the abrasivity of the rock itself. Inhomogeneous rock masses
with rock of high rock strength in combination with open / soil-filled joints or inhomogeneous
rock types with very hard components (> approx. 80 MPa) exceeding diameters of about 5 cm
(e.g. conglomerates, breccias) are the main geological factors that may cause button failure
(BB-F1). Breaking of peripheral buttons is also increased when holes have to be drilled through
steel support measures already installed - for example during forepoling through lattice arches
or during anchoring through reinforced shotcrete. BB-F2 type (total button removal) can easily
be caused by no or bad soldering of the buttons into the steel body.
Failure of the bit shaft (BB-F3) is mainly a result of manufacturing problems or bad handling.
In these cases, no conclusions may be drawn on geological circumstances.
The occurrence of thermic wear (BB-T) strongly depends on the effectiveness of the flushing
system. Under normal circumstances button bits are cooled effectively by water flushing so that
tool temperatures do not exceed 40oC. If no or insufficient flushing is available (e.g. due to prob-
lem with the flushing system, insufficient air flushing, water-mist-drilling) thermal wear may
occur. Wear types do equal those of abrasive wear and wear due to material failures. Addition-
ally, specific steel temper colours may show on the tool body if heated above 200oC and may be
used diagnostically to estimate the maximum tool temperature.
Special wear type “Total wear down” (BB-Sp1) is stated when the bit is worn below the but-
tons. In such cases it may not be possible to definitely recognise the predominant wear process.
Special wear type “Widening of flushing holes” (BB-Sp2) and flutes is a phenomenon which in
most cases is caused by aggressive flushing fluids or suspended abrasive particles. It may in
some cases even be caused by cavitation which means material loss due to forming and implo-
sion of microscopic vapour bubbles under very high velocities of flow.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 9: Drill bit lifetime for 43-45 mm button bits, plotted against CAI.
5.5 Abrasive Mineral Content (AMC), Vickers Hardness Number of the Rock
(VHNR) and Equivalent Quartz Content (EQC; Geotechnical Indices)
AMC, VHNR and EQC are very similar geotechnical parameters using petrographical thin sec-
tion analysis in order to identify abrasive minerals and their quantity in the rock. They are
calculated by multiplying the content of a mineral with a specific hardness value and then add-
ing the values up. The indices vary in the use of different hardness values: While AMC uses
Mohs scratch hardness, VHNR uses Vickers indentation hardness and EQC uses Rosiwal
grinding hardness. VHNR and EQC have proven to be suitable for drill bit lifetime calculation as
presented in Figures 10 and 11.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 10: Drill bit lifetime for different bit diame- Figure 11: Drill bit lifetime for 43-48 mm button bits
ters, plotted against VHNR (compiled according plotted against the Equivalent Quartz Content ac-
to [5], [6]). cording to [15].
A problem in using these indices is that the influence coming from different rock strengths is
primarily neglected, which means that a loose quartz sand and a metamorphic quartzite with an
extremely high Unconfined Compressive Strength would be given the same AMC, VHNR and
EQC. Newer diagrams like that one presented in Figure 11 [15] try to react to this influence by
characterising different graphs for rock types with different strength characteristics.
Figure 12: Drill bit lifetime, plotted against the modified Schimazek Index Fmod according to [8]
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Figure 13: Drill bit lifetime, plotted against RAI according to [8]
Rock mass scale factors such as fractured zones, influences coming from anisotropic rocks,
water and stress conditions may be taken into consideration in a qualitative manner on the ba-
sis of the findings presented in [8].
6 Conclusion
Assessment of tool wear and rock abrasivity is in all phases of a tunnelling or mining project a
challenging task that may only be solved by close interdisciplinary cooperation of engineers and
engineering geologists. The presented field and laboratory investigation methods can provide
valuable parameters which may help to assess rock abrasivity, to analyse and predict tool wear
and discover possible risks in hardrock drilling – in the preliminary phase of a project as well as
during operation.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
7 References
[1] Bruland, A.: Project report 13A-98 - Hard rock tunnel boring: Drillability Test methods.
NTNU Trondheim 1998.
[2] Cerchar - Centre d´ Etudes et Recherches de Charbonnages de France: The Cerchar
Abrasiveness Index. Verneul 1986.
[3] Deketh, H.J.R.: Wear of rock cutting tools - Laboratory experiments on the abrasivity of
rock. Rotterdam, Brookfield: Balkema 1995.
[4] Ewendt, G.: Erfassung der Gesteinsabrasivität und Prognose des Werkzeugverschleißes
beim maschinellen Tunnelvortrieb mit Diskenmeißeln.- Bochumer geol. u. geot. Arbeiten,
33 (1989).
[5] Johannessen, O., Jacobsen, K., Ronn, P.E. & Moe, H.L.: Project Report 2C-95 Tunnelling
Costs for Drill and Blast. NTNU Trondheim, Department of Building and Construction En-
gineering 1995.
[6] Johannessen, O., Aune, S.E., Bardal, R., Hermanstad, E. & Olsen, V.: Project Report
12C-00 Rock Quarrying Bench Drilling. NTNU Trondheim, Department of Building and
Construction Engineering 2000.
[7] Osburn, H.J.: Wear of rock cutting tools. Powder Metallurgy 12 (1969), p. 471-502.
[8] Plinninger, R.J.: Klassifizierung und Prognose von Werkzeugverschleiß bei konventionel-
len Gebirgslösungsverfahren im Festgestein. Münchner Geologische Hefte, Reihe B, 17 -
Angewandte Geologie. München: Hieronymus 2002.
[9] Plinninger, R.J., Spaun, G. & Thuro, K.: Prediction and Classification of tool wear in drill
and blast tunnelling. in: Van Rooy, J.L. & Jermy, C.A. (eds.): Engineering Geology for De-
veloping Countries, Proceedings of the 9th IAEG Congress, Durban, South Africa: p.
2226-2236. Rotterdam, Brookfield: Balkema 2002.
[10] Plinninger, R.J., Käsling, H., Thuro, K. & Spaun, G.: Testing conditions and geomechani-
cal properties influencing the CERCHAR abrasiveness index (CAI) value.-International
Journal of Rock Mechanics and Mining Sciences, 40 (2003): p. 259-263.
[11] Plinninger, R.J., Käsling, H. & Thuro, K.: Wear Prediction in Hardrock Excavation Using
the CERCHAR Abrasiveness Index (CAI). in: SCHUBERT, W. (ed): Rock engineering - the-
ory and practise, Proceedings of the ISRM regional Symposium EUROCK 2004 & 53rd
Geomechanics Colloquy: p. 599-604, Essen: Glückauf 2004.
[12] Schimazek, J. & Knatz, H.: Der Einfluss des Gesteinsaufbaus auf die Schnitt-
geschwindigkeit und den Meißelverschleiß von Streckenvortriebsmaschinen.- Glückauf,
106 (1970): p. 274-278.
[13] Schormair, N., Thuro, K. & Plinninger, R.J.: The influence of anisotropy on hard rock drill-
ing and cutting. paper No. 491. Engineering geology for tomorrow's cities - 10th IAEG
Congress, Nottingham, United Kingdom, 6-10 September 2006.
[14] Thuro, K.: Bohrbarkeit beim konventionellen Sprengvortrieb. Münchner Geologische
Hefte, Reihe B, 1 - Angewandte Geologie. München: Hieronymus 1996.
[15] Thuro, K. & Plinninger, R.J.: Hard rock tunnel boring, cutting, drilling and blasting: rock
parameters for excavatability. Proceedings of the 10th ISRM Int. Congress on Rock Me-
chanics, Johannesburg, South Africa, 8-12. September 2003: p. 1227-1234.
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R. Plinninger – Abrasivity Assessment for Hardrock Drilling
Author:
Dipl.-Geol. (Univ.) Dr.rer.nat Ralf J. Plinninger, Dr. Plinninger Geotechnik, Kirchweg 16, D-
94505 Bernried, Tel. +49 9905/7070-360, Fax: +49 9905/7070-361, email: geotech-
nik@plinninger.de
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