Experimental Study on Mechanical Specific Energy Optimization in Axial–Torsional Coupled Impact Drilling

Axial–torsional coupled impact drilling (ATCID) technology represents a promising solution for overcoming the drilling challenges posed by conglomerate formations, which are characterized by strong heterogeneity, high abrasiveness, and poor drillability. However, the optimal parameter matching relationships and their influence patterns on mechanical specific energy (MSE) remain unclear. This study employed self-developed true triaxial impact rotary rock breaking equipment with conglomerate cores from the Junggar Basin to systematically investigate the effects of weight on bit (WOB), rotational speed (RPM), axial impact frequency, and torsional impact frequency on MSE through orthogonal experimental design. The results demonstrate that the parameter influence ranking on MSE is as follows: torsional impact frequency > WOB > RPM > axial impact frequency, with torsional impact frequency exhibiting the largest range value (87.5 MPa). ANOVA reveals that the interaction between axial and torsional impact frequencies is the dominant controlling factor, contributing 22.8% to MSE variation with high statistical significance. The optimal parameter combination yields the minimum MSE (103 MPa): 19 kN WOB, 20 r/min RPM, 20 Hz axial impact frequency, and 20 Hz torsional impact frequency, representing a 69.1% reduction compared to the maximum value. Response surface analysis revealed that increasing WOB significantly reduces MSE, RPM exhibits positive correlation with MSE, and synergistic effects occur when both impact frequencies reach high values simultaneously. A nonlinear MSE prediction model incorporating main effects, quadratic terms, and interaction effects was established with R2 = 0.8240 and a mean absolute percentage error of 9.26%. The research findings provide an essential theoretical foundation for parameter optimization and engineering applications of ATCID technology, offering significant implications for enhancing drilling efficiency in conglomerate and other challenging hard rock formations.