Experimental study on the process of cutting into rock samples by full-section rectangular roadheader cutterhead

doi:10.3785/j.issn.1006-754X.2025.05.115

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (5): 720-734 DOI: 10.3785/j.issn.1006-754X.2025.05.115

Mechanical parts and equipment design

Experimental study on the process of cutting into rock samples by full-section rectangular roadheader cutterhead

Qiang LI^1,²(

),Songyong LIU¹(

),Yan WANG¹

^1.School of Mechanical and Electrical Engineering, China University of Mining and Technology, Xuzhou 221116, China
^2.School of Mechanical and Electronic Engineering, Suzhou University, Suzhou 234000, China

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Abstract

In order to achieve rapid and efficient full-section one-time forming of rectangular roadways, it is imperative to develop a full-section rectangular roadheader. For this purpose, by combining numerical analysis and motion trajectory simulation, a Reuleaux triangular cutterhead driven by an eccentric shaft planetary gear was designed for the full-section rectangular roadheader, and the test prototype was developed to conduct experimental study on the process of the cutterhead cutting into rock samples, achieving the one-time cutting and forming of a rectangular full-section by a single cutterhead. Firstly, the forming principle of rectangular cutting for the designed cutterhead was analyzed, and the perimeter and area difference rates between the vertex trajectory and the standard square were obtained. Then, in order to study the cutting characteristics of the cutterhead during the process of cutting into rock samples, a full-section rectangular cutting test bench was built, and cutting tests were conducted on the central fishtail cutter and edge cutting tool during the process of cutting into rock samples. The experimental results indicated that during the process of cutting into rock samples with the central fishtail cutter, the propulsion oil pressure, cutting torque and Y-direction vibration all showed a fluctuating increase, and their fluctuation positions were basically the same. In the low propulsion speed range (v=3?5 mm/min), as the propulsion speed increased, the growth rate of propulsion oil pressure, cutting torque and Y-direction vibration increased rapidly. In the high propulsion speed range (v=5?14 mm/min), as the propulsion speed increased, the growth rate of propulsion oil pressure, cutting torque and Y-direction vibration slowed down. Among the vibrations in the X, Y, and Z directions, the Y-direction vibration was the most representative. During the process of cutting into rock samples with the edge cutting tool, the propulsion oil pressure increased with fluctuations, but the cutting torque decreased with fluctuations due to the collaborative rock breaking of multiple tools. When the same tools cut into rock samples, the greater the strength of rock samples, the greater the cutting torque and propulsion oil pressure required by tools. When different tools cut into rock samples, the difference in cutting torque was relatively large. The average vibration generated during the process of cutting into rock samples by edge cutting tools was smaller than that of central fishtail cutters. When the compressive strength of the rock sample was 6.515?15.639 MPa, the propulsion oil pressure required to achieve full-section rectangular cutting was 3.443?3.662 MPa, the cutting torque was 44.440?49.545 N·m, and the generated Y-direction vibration acceleration was 0.006 5?0.018 0 m/s2. The research results verified the feasibility of rectangular cutting by eccentric shaft planetary gear-driven Reuleaux triangular cutterhead in practical engineering applications, which lay a foundation for the development of full-section rectangular roadheader prototypes.

Key words： full-section rectangular roadheader cutterhead cutting into rock sample central fishtail cutter edge cutting tool

Received: 20 December 2024 Published: 31 October 2025

CLC:

TD 421

Corresponding Authors: Songyong LIU E-mail: liqiang1205@163.com;liusongyong@163.com

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Cite this article:

Qiang LI,Songyong LIU,Yan WANG. Experimental study on the process of cutting into rock samples by full-section rectangular roadheader cutterhead. Chinese Journal of Engineering Design, 2025, 32(5): 720-734.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.05.115 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I5/720

全断面矩形掘进机刀盘截入岩样过程试验研究

为实现快速、高效的矩形巷道全断面一次成形，开发全断面矩形掘进机势在必行。为此，基于数形分析与运动轨迹仿真相结合的方法，设计了一种偏心轴行星齿轮驱动的勒洛三角形全断面矩形掘进机刀盘，并研制了试验样机，进行了刀盘截入岩样过程试验研究，实现了单刀盘矩形全断面一次截割成形。首先，分析了所设计刀盘矩形截割的成形原理，得到了其顶点轨迹与标准正方形的周长和面积差异率。然后，为了研究刀盘截入岩样过程中的截割特性，搭建了全断面矩形截割试验台，开展了中心鱼尾刀、边缘刀具截入岩样过程的截割试验。试验结果表明：在中心鱼尾刀截入岩样过程中，推进油压、截割扭矩、Y向振动均呈波动式增大，且三者波动的位置基本一致；在低推进速度阶段（v=3~5 mm/min），随着推进速度的增大，推进油压、截割扭矩、Y向振动的增速较快；在高推进速度阶段（v=5~14 mm/min），随着推进速度的增大，推进油压、截割扭矩、Y向振动的增速变缓；在X、Y、Z三向振动中，Y向振动最具代表性。在边缘刀具截入岩样过程中，推进油压呈波动式增大，但截割扭矩因多刀具协同破岩而呈波动式减小。当同类型刀具截入岩样时，岩样强度越大，刀具所需的截割扭矩、推进油压越大；当不同类型刀具截入岩样时，截割扭矩的差值较大；边缘刀具截入岩样过程中产生的平均振动比中心鱼尾刀小。当岩样抗压强度为6.515~15.639 MPa时，实现全断面矩形截割所需的推进油压为3.443~3.662 MPa，截割扭矩为44.440~49.545 N·m，产生的Y向振动加速度为0.006 5~0.018 0 m/s²。研究结果验证了在实际工程应用中采用偏心轴行星齿轮驱动的勒洛三角形刀盘实现矩形截割的可行性，为全断面矩形掘进机工程样机的研发奠定了基础。

关键词： 全断面矩形掘进机, 刀盘, 截入岩样, 中心鱼尾刀, 边缘刀具

Fig.1 Existing structure forms of full-section rectangular roadheader cutterhead

Fig.2 Spoke-type retractable dual-cutterhead structure

Fig.3 Five-cutter milling full-section rectangular rapid roadheader

Fig.4 Schematic of motion process of Reuleaux triangle in the square

Fig.5 Working principle of cutterhead and its motion trajectory simulation results

Fig.6 Design scheme of body structure of cutterhead cutting test bench

Fig.7 Physical picture of cutterhead cutting test bench

Fig.8 Connection and arrangement of sensors

Fig.9 Rock samples

Table 1 Determination results of mechanical properties of rock samples

Fig.10 Experimental data in the process of central fishtail cutter cutting into rock sample 1 (n=6 r/min, v=4.74 mm/min)

Fig.11 Vibration data in the process of central fishtail cutter cutting into rock sample 1 (n=6 r/min)

Fig.12 Experimental data in the process of central fishtail cutter cutting into rock sample 1 under different propulsion speeds (n=6 r/min)

Fig.13 Experimental data in the process of central fishtail cutter cutting into rock sample 2 (n=6 r/min, v=9.36 mm/min)

Fig.14 Experimental data in the process of edge cutting tool cutting into rock samples (n=6 r/min)

Fig.15 Experimental data in the process of edge cutting tool cutting into rock sample 2 under different propulsion speeds (n=6 r/min)

Fig.16 Statistical results of experimental data in the process of cutting into rock samples with different types of tools

Fig.17 Cutting sections of rock samples and tool path

Table 2 Comparison of actual contour and simulated contour of cutting section of rock samples

Table 3 Comparison between designed cutterhead and other existing rectangular cutterheads


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