Search for Author, Title, Keyword
RESEARCH PAPER
Cutting load analysis and Optimization methods of the Bauxite Shearers
,
 
,
 
,
 
,
 
,
 
 
 
More details
Hide details
1
Shandong University of Science and Technology, China
 
2
State Key Laboratory of Intelligent Coal Mining and Strata Control, Shanghai, China
 
 
Submission date: 2024-09-30
 
 
Final revision date: 2024-12-17
 
 
Acceptance date: 2025-02-15
 
 
Online publication date: 2025-02-21
 
 
Publication date: 2025-02-21
 
 
Corresponding author
Shuxue Wang   

Shandong University of Science and Technology, China
 
 
Eksploatacja i Niezawodność – Maintenance and Reliability 2025;27(3):201464
 
HIGHLIGHTS
  • Comparison of uniaxial compression and linear cutting tests with numerical simulations.
  • Comparative Analysis of the Forces Acting on Each Conical Pick.
  • Analysed the impact of the arrangement of vane conical picks on the cutting performance.
  • Analysed the impact of radial retraction of end plate picks on the cutting performance.
KEYWORDS
TOPICS
ABSTRACT
Bauxite shearers frequently face challenges such as difficult drum traction, significant load fluctuations, and a short lifespan of conical picks during operation, all of which adversely affect equipment stability. To improve the reliability of the bauxite shearers, rock fragmentation tests were conducted using a servo press and a cutting test equipment. The finite element method is employed to simulate the working process of the drum in order to determine the forces acting on both the total drum and each individual conical pick. Additionally, a method aimed at reducing the force on the drum is proposed and simulated. The research results indicate that the traction resistance of the drum can be reduced and the stability of equipment operation can be increased by appropriately increasing the cutting distance of the vane conical picks, adopting a sequential conical picks arrangement method, and retracting the end plate conical picks.
REFERENCES (34)
1.
Shaofeng W, Xibing L and Wang S. Three-dimensional mineral grade distribution modelling and longwall mining of an underground bauxite seam. International Journal of Rock Mechanics and Mining Sciences (Oxford, England : 1997) 2018; 103: 123-136. DOI: 10.1016/j.ijrmms.2018.01.035. https://doi.org/10.1016/j.ijrm....
 
2.
Nahak S, Chattopadhyaya S and Dewangan S, et al. MICROSTRUCTURAL STUDY OF FAILURE PHENOMENA IN WC 94%-Co 6% HARD METAL ALLOY TIPS OF RADIAL PICKS. Advances in Science and Technology Research Journal 2017; 11: 36-47. DOI: 10.12913/22998624/68457.
 
3.
Wang Z and Zhang L. Mining Machines for Comprehensive Mechanized Mining of Bauxite. Journal of Physics. Conference Series 2023; 2557: 12018. DOI: 10.1088/1742-6596/2557/1/012018. DOI 10.1088/1742-6596/2557/1/012018.
 
4.
Fan Q, Zhang Q and Liu G. A Stress Analysis of a Conical Pick by Establishing a 3D ES-FEM Model and Using Experimental Measured Forces. Applied Sciences 2019; 9: 5410. DOI: 10.3390/app9245410.
 
5.
Li X, Wang Z and Zeng Q, et al. Experimental and Numerical Studies on Rock Cutting with Saw Blade and Conical Pick Combined Cutting Method. Math. Probl. Eng. 2019; 2019: 1-14. DOI: 10.1155/2019/5046873.
 
6.
Lu Z, Zeng Q and Meng Z, et al. Numerical Research on Cutting Force and Fracture Morphology of Rock Plate with Two Sides Fixed and Two Sides Free. Math. Probl. Eng. 2020; 2020: 1-14. DOI: 10.1155/2020/8652637.
 
7.
Qiao S, Xia Y and Liu Z, et al. Finite element analysis of load characteristic of shield bolter miner cutting head under complex coal seam condition. Mining Science (Wroclaw) 2017; 24: 85. DOI: 10.5277/msc172405.
 
8.
Liu X, Liu S and Ji H. Mechanism of rock breaking by pick assisted with water jet of different modes. J. Mech Sci Technol 2015; 29: 5359-5368. DOI: 10.1007/s12206-015-1137-3.
 
9.
Wen S, Du L, Kong Q, Zhang M, Ding X. Study on Microwave-assisted TBM Double-edged Cutter Rock-breaking Efficiency and its Positional Relationship. Eksploatacja i Niezawodność – Maintenance and Reliability. 2024;26(2). doi:10.17531/ein/186447.
 
10.
Zhang X, Li J, Li X, Li Q. Cutting Characteristics and Reliability Analysis of Conical Picks Containing Prefabricated Grooved Rocks. Eksploatacja i Niezawodność – Maintenance and Reliability. 2024;26(4). doi:10.17531/ein/191694.
 
11.
Xiang W, Su O and Qingfeng W. Distribution characteristics of rock chips under relieved and unrelieved cutting conditions. International Journal of Rock Mechanics and Mining Sciences (Oxford, England : 1997) 2022; 151: 105048. DOI: 10.1016/j.ijrmms.2022.105048.
 
12.
Dogruoz C, Bolukbasi N and Rostami J, et al. An experimental study of cutting performances of worn picks. Rock Mech. Rock Eng. 2016; 49: 213-224. DOI: 10.1007/s00603-015-0734-x.
 
13.
Tan H, Liu ZQ and Tan J, et al. Drilling parameters optimization of pick-shaped TCT for raising boring construction of Feng Ning pumped storage power station. IOP Conference Series. Earth and Environmental Science 2019; 237: 62023. DOI: 10.1088/1755-1315/237/6/062023.
 
14.
Qiao S, Zhang ZQ and Zhu ZM, et al. Influence of cutting angle on mechanical properties of rock cutting by conical pick based on finite element analysis. Mining Science (Wroclaw) 2021; 28: 161. DOI: 10.37190/msc212812.
 
15.
Lu Z, Wan L and Zeng Q, et al. The structural optimization of roadheader conical picks based on fatigue life. International Journal of Modeling, Simulation, and Scientific Computing 2018; 09: 1850013. DOI: 10.1142/S1793962318500137.
 
16.
Liu SF, Lu SF and Wan ZJ, et al. Investigation of the influence mechanism of rock damage on rock fragmentation and cutting performance by the discrete element method. Roy Soc Open Sci 2019; 6: 190116. Journal Article. DOI: 10.1098/rsos.190116.
 
17.
Hu X, Jiang H and Du C. Finite element method for prediction of rock breaking performance of the tipped hob with different tooth profiles. Ieee Access 2020; 8: 1. DOI: 10.1109/ACCESS.2020.2980427.
 
18.
Wang Z, Zeng Q and Lu Z, et al. Numerical Simulation of Conical Pick Cutting Arc Rock Plate Fracture Based on ANSYS/LS‐DYNA. Adv Mater Sci Eng 2020; 2020. DOI: 10.1155/2020/6563520.
 
19.
Shaofeng W, Xibing L and Kun D, et al. Experimental investigation of hard rock fragmentation using a conical pick on true triaxial test apparatus. Tunn. Undergr. Sp. Tech. 2018; 79: 210-233. DOI: 10.1016/j.tust.2018.05.006.
 
20.
Wang S, Li X and Yao J, et al. Experimental investigation of rock breakage by a conical pick and its application to non-explosive mechanized mining in deep hard rock. Int. J. Rock Mech. Min. 2019; 122: 104063. DOI: 10.1016/j.ijrmms.2019.104063.
 
21.
Wang S, Huang L and Li X. Analysis of rockburst triggered by hard rock fragmentation using a conical pick under high uniaxial stress. Tunn. Undergr. Sp. Tech. 2020; 96: 103195. DOI: 10.1016/j.tust.2019.103195.
 
22.
Li X. A study on the influence of pick geometry on rock cutting based on full-scale cutting test and simulation. Adv Mech Eng 2020; 12: 2072266537. DOI: 10.1177/1687814020974499.
 
23.
Tian Z, Gao S and Jing S, et al. Reliability and fatigue life analysis of key parts of shearer. Eng. Fail. Anal. 2022; 138: 106357. DOI: 10.1016/j.engfailanal.2022.106357.
 
24.
Liu X, Liu S and Tang P. Coal fragment size model in cutting process. Powder Technol. 2015; 272: 282-289. DOI: https://doi.org/10.1016/j.powt....
 
25.
Zhang M, Yan X and Qin G. A new method for roadheader pick arrangement based on meshing pick spatial position and rock cutting verification. Plos One 2021; 16: e0260183.https://doi.org/10.1371/journa....
 
26.
Li HS, Liu SY and Xu PP. Numerical simulation on interaction stress analysis of rock with conical picks. Tunn. Undergr. Sp. Tech. 2019; 85: 231-242. DOI: 10.1016/j.tust.2018.12.014.
 
27.
Liu S, Ji H and Liu X, et al. Experimental research on wear of conical pick interacting with coal-rock. Eng. Fail. Anal. 2017; 74: 172-187. DOI: 10.1016/j.engfailanal.2017.01.013.
 
28.
Bilgin N, Demircin MA and Copur H, et al. Dominant rock properties affecting the performance of conical picks and the comparison of some experimental and theoretical results. International Journal of Rock Mechanics and Mining Sciences (Oxford, England : 1997) 2006; 43: 139-156. DOI: 10.1016/j.ijrmms.2005.04.009.
 
29.
Su O and Ali Akcin N. Numerical simulation of rock cutting using the discrete element method. Int. J. Rock Mech. Min. 2011; 48: 434-442. DOI: 10.1016/j.ijrmms.2010.08.012.
 
30.
Li X, Wang S and Malekian R, et al. Numerical Simulation of Rock Breakage Modes under Confining Pressures in Deep Mining: An Experimental Investigation. Ieee Access 2016; 4: 5710-5720. DOI: 10.1109/ACCESS.2016.2608384.
 
31.
Zhao L, Jin X and Liu X. Numerical research on wear characteristics of drum based on discrete element method (DEM). Eng. Fail. Anal. 2020; 109: 104269. DOI: 10.1016/j.engfailanal.2019.104269.
 
32.
Krauze K, Bołoz A and Wydro T, et al. Investigations into the wear rate of conical picks with abrasion-resistant coatings in laboratory conditions. IOP Conference Series. Materials Science and Engineering 2019; 679: 12012. DOI: 10.1088/1757-899X/679/1/012012.
 
33.
Li X, Wang S and Ge S, et al. A study on drum cutting properties with full-scale experiments and numerical simulations. Measurement 2018; 114: 25-36. DOI: 10.1016/j.measurement.2017.09.006.
 
34.
Dewangan S, Chattopadhyaya S and Hloch S. Wear assessment of conical pick used in coal cutting operation. Rock Mech. Rock Eng. 2015; 48: 2129-2139. DOI: 10.1007/s00603-014-0680-z.
 
eISSN:2956-3860
ISSN:1507-2711
Journals System - logo
Scroll to top