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How Can We Make Best…Better: Using Abaqus and Isight to Optimize Tools for Downhole Expandable Tubulars

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The use of expandable tubulars has emerged as a popular technology for drilling and completing wells. While expandable tubulars vary in type depending upon the application and specific well requirements, the most common approach is to actually form the metals downhole, which presents unprecedented challenges for tool designers. The costs and timelines to achieve a “workable” product can be tremendous. The Abaqus and Isight simulators effectively address these impediments and have been proven to be invaluable tools for enhancing understanding of the mechanics and effects of nonlinear/dynamic expansion of metals. In this presentation, the author reviews some of the challenges that had to be overcome in engineering these expandable products. Abaqus has been used to simulate expansion of threaded connections and was instrumental in optimizing the latest expandable thread designs. Meanwhile, Abaqus was used in conjunction with Isight to optimize the geometry of the next generation of expandable cones for the expansion of downhole tubulars. While these applications tested engineering intuition, the two simulation tools cleared the way for the development of an improved approach to downhole expandable tubulars.

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