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<p>Addressing unclear grinding mechanisms and the lack of theoretical guidance for optimal tubing milling shoe design, this study established a thermo-mechanical coupling simulation model for a single abrasive particle using a temperature-displacement coupling algorithm and Johnson–Cook constitutive and damage models. The model was used to investigate the effects of abrasive particle type and inclination angle on tubing milling performance. The results show that abrasive particle geometry strongly influences the material removal mechanism. Circular particles are suitable for conditions with poor carrying debris capacity but exhibit lower efficiency, while square particles provide the highest efficiency but are prone to chip accumulation. Octagonal particles offer a favorable balance between efficiency and chip control. The cutter inclination angle affects stability and energy consumption by modifying the force transmission path. Square particles perform best at inclination angles of 3.5° to 7°, whereas circular and octagonal particles perform better at lower angles of 0° to 3.5°. Based on the relationship between particle geometry and inclination angle, optimized solutions for different working conditions are proposed. This study provides a theoretical foundation and data support for the optimal design and process parameter selection of tubing milling shoes.</p>

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Influence of milling shoe abrasive particle type and inclination angle on tubing grinding

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Bao Zhang,
  • Xiaotong Yu,
  • Junhui Wei,
  • Zhaocai Pan,
  • Xuan Zhou,
  • Defei Chen,
  • Zhixiong Tu

摘要

Addressing unclear grinding mechanisms and the lack of theoretical guidance for optimal tubing milling shoe design, this study established a thermo-mechanical coupling simulation model for a single abrasive particle using a temperature-displacement coupling algorithm and Johnson–Cook constitutive and damage models. The model was used to investigate the effects of abrasive particle type and inclination angle on tubing milling performance. The results show that abrasive particle geometry strongly influences the material removal mechanism. Circular particles are suitable for conditions with poor carrying debris capacity but exhibit lower efficiency, while square particles provide the highest efficiency but are prone to chip accumulation. Octagonal particles offer a favorable balance between efficiency and chip control. The cutter inclination angle affects stability and energy consumption by modifying the force transmission path. Square particles perform best at inclination angles of 3.5° to 7°, whereas circular and octagonal particles perform better at lower angles of 0° to 3.5°. Based on the relationship between particle geometry and inclination angle, optimized solutions for different working conditions are proposed. This study provides a theoretical foundation and data support for the optimal design and process parameter selection of tubing milling shoes.