Forming Optimisation And Mechanical Analysis Of An Expandable Profile Liner For Leakage Plugging In Oil And Gas Wells

The preliminary application of expandable profile liner technology (EPLT) provides an effective solution for operational challenges associated with borehole instabilities and drilling troubles control without wellbore shrinkage. This study simulates the forming and expansion processes of four kinds of differently cross-sectional shapes of expandable profile liners (EPLs) by using the finite element software ABAQUS. The results of the simulation reveal that the eight-shaped cross section has lower residual stress, better forming stability, and easier expansion characteristics. Aiming to attain the cross section with minimum residual stress and strain, we studied two forming processes with considering the mould assemblies, loading sequences, and loading displacements to optimise the section shape of a phi 241.3 mm EPL, which is meaningful for engineering applications. By simulating and analysing the expansion process of EPLs made of three different materials with three different wall thicknesses, this study obtains data on the internal pressure strength and collapse strength to provide a basis for selecting the best EPL to meet the engineering strength requirements. [Received: October 29, 2018; Accepted: August 7, 2020]