Cutting attitude inclination angle and rock-breaking mode characteristics of disc cutter
LIU Chunsheng;CHENG Shuo;LIU Yanting;XU Peng;LIU Ruohan;HAO Xin
刀具破岩模式识辨是提高截割能力的关键基础,而刀具截割姿态对破岩模式影响显著,探究截割姿态与破岩模式之间的内在关联,反演低能耗、高效能破岩的最佳截割姿态参数。基于碟盘刀具轴向向上振动时楔面作用岩石的大块崩落状态,在非线性岩石破坏准则的基础上,根据Mohr-Coulomb准则给出了岩石拉剪耦合破坏条件,扩展延伸成三段式线性岩石破坏全域准则(拉破坏、拉剪耦合破坏、剪破坏、压剪耦合破坏和压破坏),给出了不同破岩模式下刀具楔面挤压应力的数学描述,基于楔面作用的最小能量原则提出了破岩模式识辨方法,构建了刀具倾斜姿态截割岩石的载荷模型,并通过数值模拟和实验分析了不同截割姿态倾角下刀具载荷特性和岩石破碎特征(岩石块率分布和粉尘粒度分布)与破岩模式之间的关联特性。结果表明:碟盘刀具楔面能耗表征值与姿态倾角呈正比,破岩模式由拉剪耦合破坏向压剪耦合破坏转变;振动截割时刀具楔面能耗表征值明显小于无振动截割,且多以拉剪耦合破坏为主,而无振动截割时拉剪、压剪耦合破坏近似等比存在;当轴向速度楔面分量大于进给速度楔面分量时,摩擦力转变为破岩助力,楔面能耗明显下降;碟盘刀具破碎岩石宏观形态呈大块月牙状,岩粉细观形态呈类多面体和类球状,刀具姿态倾角与岩石碎片量呈反比,与岩粉量呈正比(类球状粉尘减少、类多面体粉尘增加),表明姿态倾角增大,刀具齿刃碾挤压作用减弱,楔面挤压产生粉尘能耗增加,与破岩模式识辨过程中截割姿态对楔面能耗的影响规律相一致;碟盘刀具径向载荷与姿态倾角呈下凹规律,理论和模拟与实验径向载荷规律具有一致性,其平均误差分别为8.46%和9.55%,验证了碟盘刀具破岩模式识辨方法、倾斜姿态截割岩石的载荷模型和数值模拟的合理性。
The identification of rock-breaking mode is a key basis to improve cutting ability, and the cutter cutting attitude has a significant influence on rock-breaking mode. In this study, the internal relationship between cutting attitude and rock-breaking mode was explored, and the optimal cutting attitude parameters of low energy consumption and high efficiency rock-breaking were inferred. Based on the massive collapse state of the wedge surface acting rock when disc cutter vibrates axially upward, the rock tensile-shear coupling failure condition was given according to the Mohr-Coulomb criterion on the basis of the nonlinear rock failure criterion, and the three-segment linear rock failure global criterion (tensile failure, tensile-shear coupling failure, shear failure, compression-shear coupling failure and compression failure) was obtained. The mathematical description of the cutter wedge surface compressive stress under different rock-breaking modes was got. Based on the principle of minimum energy of the wedge surface action, the identification method of rock-breaking mode was proposed, and the load model of cutting rock with disc cutter of oblique attitude was constructed. The correlation between load characteristics of the cutter, rock-crushing characteristics (rock fragmentation distribution and dust size distribution) and rock-breaking mode under different cutting attitude inclination angles was analyzed by numerical simulation and experiment. The results show that the characterization values of wedge surface energy consumption of disc cutter are proportional to the attitude inclination angle, and rock-breaking mode changes from tensile-shear coupling failure to compressive-shear coupling failure. The characterization values of wedge surface energy consumption of disc cutter in vibration cutting are obviously less than that in non-vibration cutting, and it is mainly caused by tensile-shear coupling failure, while the tension-shear and compression-shear coupling failure exists approximately in equal proportion in non-vibration cutting. When the wedge surface component of axial velocity is greater than that of feed velocity, the friction is transformed into rock-breaking assistance, and the energy consumption of the wedge surface is significantly reduced. The macroscopic morphology of disc cutter breaking rock is like the large crescent shape, and the microscopic morphology of the rock powder is like polyhedron and spheroid. The attitude inclination angle of the cutter is inversely proportional to the amount of the rock fragments, and is proportional to the amount of the rock powder (spherical-like dust decreases and polyhedron-like dust increases). It indicates that as the attitude inclination angle increases, the extrusion effect of the cutter teeth edge is weakened, and the energy consumption of dust generated by the wedge surface extrusion increases, which is consistent with the influence of the cutting attitude on the energy consumption of the wedge surface during the identification process of rock-breaking mode. The radial load and the attitude inclination angles of disc cutter are concave, the theory and simulation are consistent with the experimental radial load law, and the average errors are 8.46% and 9.55%, respectively. The rationality of the identification method of disc cutter rock-breaking mode, the load model of cutting rock with inclined attitude and the numerical simulation is verified.
disc cutter;cutting attitude;rock-breaking mode;stress coupling failure;fragmentation characteristics
主办单位:煤炭科学研究总院有限公司 中国煤炭学会学术期刊工作委员会