Investigation of Thermal Conductivity and Wear Resistance in Bio-Inspired Pitted Pistons for Enhanced Performance in Drilling Mud Pumps

Abstract

In the demanding environment of drilling mud pumps, failures attributed to piston wear constitute approximately 80% of malfunctioning incidents. While enhanced structural designs and superior materials have been employed, enduring challenges remain. A potential solution identified in previous works is surface texturing, specifically the optimization of pit structures on piston rings, with promising outcomes in friction reduction. Yet, the vital role of thermal parameters in high-intensity environments like mud pumps has been largely overlooked. In this study, the dung beetle's irregular pit structure, known for friction reduction by minimizing soil contact, is utilized as a biological model. The impact of pit geometry, including diameter, angle, and depth, on thermal conductivity, heat transfer, cooling, and heat dissipation has been thoroughly investigated. Preliminary analyses were conducted to gauge the effects of pit diameter on thermal conductivity and piston lifespan. Subsequent analyses were focused on the influence of pit angle in determining thermal gradients across the piston, and its effect on durability. Further investigation was performed to assess the implications of pit depth on heat dissipation and piston longevity. Utilizing Ansys software, the thermal and wear resistance mechanisms of the pitted piston were examined, revealing an enhancement in lifespan by up to 40.60% in comparison to non-pitted counterparts. These findings contribute to the broader comprehension of the interplay between surface texture, thermal performance, and wear resistance, heralding new avenues for thermal management in diverse mechanical machinery. The presented study lays a foundational framework for further research and represents a significant advancement towards a new generation of thermally efficient, wear-resistant mechanical components inspired by nature's perfected mechanisms.