InFocus Energy Services, Inc.
DEVELOPING DOWNHOLE OIL AND GAS DRILLING PRODUCTS FASTER WITH SIMULIA STRUCTURAL SIMULATION ENGINEER
SIMULATING TRICKY, COMPLEX CONTACT ACCURATELYInFocus first utilized SIMULIA Structural Simulation Engineer on the bearing section of the company’s RE|FLEX Premium HP/HT Drilling Motor. The motor’s bearing section is a proprietary design that was developed to convert extreme loading parameters, including torque of over 30,000 foot-pounds, into efficient drilling action. The company’s initial concept design of the drive system, which utilized traditional ball bearings, resulted in failure during testing when the load crushed the bearings and the faces that load the bearings. SIMULIA Structural Simulation Engineer predicted the failure—with accurate correlation to actual test results—and helped the company develop a better, more innovative design. “With Structural Simulation Engineer, we were able to evaluate a range of geometric and material options, a process that helped us quickly optimize the tapered, barrel-shaped design of the bearings, and also decide the best high-strength steel for the design,” Kjellbotn recalls. “Because we analyzed our options in software, we didn’t need to physically test all of the possibilities and ran just a few verification tests on the design validated in Structural Simulation Engineer, which confirmed that our simulation results were accurate. This allowed us to optimize critical internal components for cyclic fatigue-loading [bending stress], a common cause of twist-offs downhole, and confirm a higher torque rating and increased durability for our product.”
DEVELOPING UNIQUE, INNOVATIVE PRODUCTS QUICKLY AND AFFORDABLYThe experience using SIMULIA Structural Simulation Engineer software to develop the bearing section of the RE|FLEX Premium Drilling Motor is representative of the fast, focused development process that InFocus needs to introduce industry innovations in a timely, consistent fashion. “We can develop more products quicker and at lower cost by using Structural Simulation Engineer,” Kjellbotn stresses. “For example, on the bearing section of the RE|FLEX Motor, if we had had to physically test all of our design options instead of evaluating them in Structural Simulation Engineer, it would have taken a lot more time and money,” Kjellbotn says. “To do all of those tests on a high-strength drive shaft—at a cost of thousands of dollars per test—would have blown both the schedule and budget. We saved tens of thousands of dollars, months of time, and extra labor costs by using Structural Simulation Engineer. It helped us condense a process that would usually take months into just a few weeks.”
GREATER AGILITY AND FLEXIBILITY FUEL GROWTHThe implementation of SIMULIA Structural Simulation Engineer provides InFocus with the increased agility and flexibility that it needs to continue to innovate and grow. “Getting the products out and into the market faster is everything to us,” Pearson says. “Structural Simulation Engineer fits into our goal to go from concept to completion in a week. Our business needs change quickly, so having an agile system that gets results that we can trust quickly is extremely important for our continued growth.” “Because Structural Simulation Engineer is on the 3DEXPERIENCE platform in the cloud and is fully compatible with our SOLIDWORKS modeling data, it provides additional advantages,” Kjellbotn adds. “It’s hardware-independent, freeing up our workstations for other things, and utilizes SOLIDWORKS data, saving time and money because we don’t have to go through time-consuming import/export protocols. The solution also automatically stores data in the cloud and supports collaboration. With Structural Simulation Engineer, we are only limited by our imagination.”
Leverage high-end, nonlinear structural simulation technology to reduce reliance on costly, time-consuming physical testing and develop innovative downhole drilling products more quickly and cost-effectively.
Add SIMULIA Structural Simulation Engineer to its SOLIDWORKS implementation to conduct nonlinear structural and complex contact analyses in the cloud to advance and accelerate new product development.
- Saved tens of thousands of dollars in testing costs
- Realized close correlation between simulation and testing results
- Cut months of time and extra labor from development process
- Saved money spent on unnecessary mold iterations