To reveal the mechanism of free-surface rock cutting by a disc cutter and study the effect of cutting parameters on rock cutting performance, a numerical model of rock breakage by a disc cutter is established with the particle flow code (PFC). The numerical model of rock breakage by a disc cutter has been verified by rock breaking tests and can satisfactorily reproduce the rock cutting process. Hence, a numerical model was used to further study the rock breaking mechanism and effects of cutting parameters. The obtained results show that the penetration force first linearly increases and then instantaneously declines. The crushing zone gradually formed with increasing penetration force, and after that, the main crack within the rock rapidly extended to the free surface, which resulted in a decline in the penetration force. The formation of the crushing zone and main crack propagation were influenced by compression stress and tension stress, respectively, and the dissipation of energy was mainly in the stage of crushing zone formation. The peak penetration force has a linear relationship with breaking depth. The specific energy first increases and then decreases with increasing breaking depth, and the minimum value is in the range of 20–25 mm. With increasing tip width, the peak penetration force linearly increases, and the specific energy first increases and then decreases. The optimal rock breaking performance was obtained when the tip width was approximately 1 mm. Compared with the traditional rock breaking method, the preslotting method can significantly reduce the cutter load. When the breaking depth is 20 mm, the peak penetration force under the condition with a preslotting depth of 5 mm decreases by over 87% compared to that without preslotting. The preslotting method provides a potential approach for efficiently breaking hard and extremely hard rock.
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