Dynamic Behavior and Structural Optimization of Drilling Rig Masts Using Composite and Metallic Materials: A Finite Element Approach

This study investigates the dynamic behavior and structural optimization of hydraulic water well drilling rig masts through a comparative finite element analysis (FEA) of metallic and composite configurations. The reference model, manufactured from structural steel (S355J2/E315), was compared with two optimized lightweight alternatives made of carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) laminates. Simulations were performed in MSC Visual Nastran using identical geometric and loading conditions, including the critical dynamic event of drill string pull-out. The results demonstrate that substituting steel with composite materials significantly decreases the overall mass by up to 55%, while increasing the first natural frequency by 20–25% and reducing dynamic stress amplification by approximately 15–20%. Furthermore, the maximum tip displacement of the mast was reduced by 35–45% for the composite variants, indicating improved stiffness and vibration damping capability. These findings confirm that polymer composite structures offer superior dynamic performance, lower inertial loads, and enhanced operational safety, providing a viable route for next-generation lightweight drilling rig designs integrating advanced macromolecular materials.