Abstract
Crack initiation characteristics of ring chain of heavy-duty scraper conveyor under time-varying loads were investigated in this study. The dynamic tension of ring chain of the heavy-duty scraper conveyor was obtained using the time-varying dynamic analysis. Finite element analyses of three-dimensional contacts between adjacent chain rings at straight and bending segments were carried out to explore three-dimensional stress distributions of chain rings. The crack initiation life of chain ring was predicted employing the multiaxial fatigue theory. The results show that the ring chain is subjected to time-varying dynamic tensions during operation. During tension-tension contact fatigue, as compared to the straight segment of ring chain, the bending segment engaging in the sprocket presents an overall lower (or higher) equivalent stress distribution in the case of flat (or vertical) chain ring, respectively. Maximum equivalent stresses at the contact regions of adjacent chain rings both present time-varying dynamic characteristics similar to evolutions of dynamic tension. During tension-torsion contact fatigue, an increase in torsion angle level causes unobvious difference between equivalent stress distributions at contact regions of adjacent rings. Predicted crack initiation lives of chain rings during tension-tension contact fatigue indicates more severe fatigue damages of the vertical chain ring at the straight segment and of the flat chain ring at the right bending segment.
Highlights
The scraper conveyor, as the key transportation equipment in fully mechanized mining face, is responsible for carrying the coal, providing the running track for the shearer, and providing the moving fulcrum for the hydraulic support.[1]
The ring chain is one of the key components that affects the normal operation of scraper conveyor
40% of downtime of heavy-duty scraper conveyor is caused by the fracture of ring chain
Summary
The scraper conveyor, as the key transportation equipment in fully mechanized mining face, is responsible for carrying the coal, providing the running track for the shearer, and providing the moving fulcrum for the hydraulic support.[1]. During the operation of heavy-duty scraper conveyor, the ring chain is subjected to the time-varying dynamic tension attributed to the polygon effect between sprocket and ring chain, alternating change between empty and full loads, and frequent start-up or shutdown at full-loaded and overload states. The objective of this study is to investigate the crack initiation characteristics of ring chain of heavy-duty scraper conveyor under time-varying loads. According to design parameters of the typical heavy-duty scraper conveyor (Table 1) and material parameters of ring chain (Table 2), the evolution of dynamic tension of ring chain during the stabilized operation can be obtained using equation (1) (Table 2). The flat ring, semi-vertical ring, and wheel tooth have elements of 17,150, 8722, and 10,462, respectively, and nodes of 19,208, 9950, and 12,313, respectively
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