Abstract
This paper presents a procedure for an accurate and reliable stress analysis in a conical pick used in mining operations, aiming to improve their wear resistance. This is achieved by (1) establishment of a three-dimensional (3D) edge-based smoothed finite element method (ES-FEM), and algorithms of creating the smoothing domain for accurate solution in terms of stress and strain distributions; and (2) use of experimentally measured actual forces using a full-scale rotary cutting machine. In our 3D ES-FEM model, the physical domain for the pick is first discredited using linear triangular elements that can be generated easily for complicated geometries. The smoothing domains are then constructed based on edges of these elements in an automated fashion. In order to create the smoothing domains for the smoothed strain computation in the ES-FEM, an algorithm is presented for establishing connection between nodes, edges, faces, and elements. Each smoothing domain is bounded by a set of enclosed line-segments, besides, leading to a connectivity list for later effective computation. To show the effectiveness and accuracy of the strain energy and the displacement solution of ES-FEM, based on the actually measured forces from the laboratory rock cutting tests with a single pick, a comparison study is carried out against the standard finite element method (FEM). It can be concluded that ES-FEM has a higher convergence in energy norm and better accuracy than FEM using the same mesh from the comparison results. The 3D ES-FEM model solves the problem of the lower solution accuracy, caused by the poor quality of mesh, by using the standard FEM in solving the stress distribution of mining machinery parts, such as picks, and offers accurate and reliable solutions that are critical for improving the wear resistance of the pick for the mining industry.
Highlights
An imbalance in the excavation ratio has been a major obstacle affecting the safe and efficient production of coal
The 3D edge-based smoothed finite element method (ES-finite element method (FEM)) model solves the problem of the lower solution accuracy, caused by the poor quality of mesh, by using the standard FEM in solving the stress distribution of mining machinery parts, such as picks, and offers accurate and reliable solutions that are critical for improving the wear resistance of the pick for the mining industry
The geometrical parameters of the practical conical pick used in our experiment are given in of other S-FEM models and FEM in stress, strain energy, and displacement
Summary
An imbalance in the excavation ratio has been a major obstacle affecting the safe and efficient production of coal. When the mesh is distorted, the result will become worse, and even in the standard FEM program it will break down because of the poor quality of the Jacobian matrix In consideration of these problems, smoothed finite element methods (S-FEMs) [19] have been developed using the strain smoothing technique, which has been developed based on G space theory [20,21] and weakened weak form (W2 form). T4 elements are employed as the the stress and strain distributions of the conical pick, which can better master its working condition background mesh and the edge-based smoothing domains are created based on it. The stress and strain distributions for conical picks are calculated, and the values of with experimental measured forces were given and some comparisons with other S-FEM models and nodal displacement are calculated. Measured forces were given and some comparisons with other S-FEM models and FEM were made
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