Abstract
Various numerical methods have been used to simulate the rock cutting process. Numerical simulation is a useful tool for estimating the performance of a cutting tool and for understanding the mechanism of rock cutting and interaction between a cutting tool and the rock. These methods supplement the rock cutting test, which is commonly referred to as the linear cutting machine (LCM) test. Mechanical excavators, such as roadheaders, longwall shearers, and trenchers, generally use pick cutters as the cutting tool. In this study, a rock cutting simulation with a pick cutter was developed using the smooth particle hydrodynamics (SPH) technique, which is a mesh-free Lagrangian method. The Drucker–Prager (DP) strength model was used to simulate the brittle behavior of rock. The cumulative damage (CD) model was used to simulate the degraded fragmentation process of rock and the distinctive behavior of rock in the compression and tensile stress regions. In this study, an attempt was made to simulate sequential cutting by multiple pick cutters. The results showed that the numerical simulation matched the experimental results closely in terms of cutter forces, specific energy, and the fragmentation phenomenon. These results confirmed the applicability of the SPH technique in simulating the rock cutting process.
Highlights
The mechanical excavation method has been used in many civil and mining projects
At the point point of contact with the pick cutter, the rock fragmentation and stress distribution are affected by the of contact with the pick cutter, the rock fragmentation and stress distribution are affected by the penetration depth, whereas the rock fragmentation pattern between adjacent cutters depend on the penetration depth, whereas the rock fragmentation pattern between adjacent cutters depend on the cut cut spacing
The rock cutting process of a point attack pick was simulated numerically using AUTODYN-3D, and the cutting efficiency was evaluated for several cutting conditions using a proposed numerical model
Summary
The mechanical excavation method has been used in many civil and mining projects. It is becoming increasingly popular due to its numerous advantages over the drill and blasting method in terms of safety, stability, high advance rate, and less environmental impact. The important design parameters of mechanical excavators are the arrangement of cutting tools, thrust, torque, and rotational speed of the cutterhead. These design parameters should be estimated carefully by considering the effect of the cutting conditions (i.e., penetration depth (p), cut spacing (s), and cutting angle) on the cutting force, cutting efficiency, and mechanical stability of a machine [1,2]. The linear cutting machine (LCM) test is well-known as an accurate and reliable method for evaluating the design parameters of mechanical excavators [3,4,5,6,7,8]. The full-scale LCM test is the most reliable method for determining the design parameters of different machines, it usually requires full-size specimens of rock, which makes the test expensive and time-consuming [9,10,11]
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