Baker Hughes Expandable Tubular FEA Optimization Using Abaqus and Isight
Case study showing how Baker Hughes used Abaqus FEA and Isight process automation to optimize segmented expansion cone geometry for expandable tubulars.
Baker Hughes applied finite element analysis with Abaqus and automated design optimization with Isight to refine cone geometry for high-torque, gas-tight expandable tubular connections. The workflow replaced months of manual FEA iterations with a two-day DOE process that evaluated hundreds of design variants. The resulting OPTI-Cone geometry performed across multiple thread configurations where previous manual designs had failed. The approach also enabled earlier virtual validation of downhole tools such as anchor slips and extrudable ball seats.
Abaqus FEA modeled nonlinear expansion physics including hoop stress, Bauschinger effect, and bend/rebend behavior in expandable tubulars.
Isight automated design of experiments, reducing cone geometry optimization from two months to two days.
The OPTI-Cone design reused previously discarded geometry and achieved acceptable performance on multiple thread connections.
Virtual testing shifted real-world prototype validation later in the development cycle, lowering cost and risk.
Process automation freed engineering hours for additional product configurations and new market opportunities.
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