Study on deformation law of rocker arm shell of shearer based on EDEM-ADAMS

doi:10.3785/j.issn.1006-754X.2025.04.169

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (2): 220-231 DOI: 10.3785/j.issn.1006-754X.2025.04.169

Reliability and Quality Design

Study on deformation law of rocker arm shell of shearer based on EDEM-ADAMS

Liyong TIAN(

),Xiaohan YU(

),Ning YU

School of Mechanical Engineering, Liaoning Technical University, Fuxin 123000, China

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Abstract

In order to analyze the root of shearer rocker arm shell failure and ensure the safe and stable operation of shearer, the influencing factors of shearer rocker arm shell deformation were analyzed, and the shell deformation law was studied.Firstly, the mechanical model of the rocker arm shell was constructed, and the load factors affecting the deformation of rocker arm shell were sorted out, including the external forces generated by coal rock on the drum and the internal loads formed by gear transmission system when the shearer was cutting. Secondly, Solidworks software was used to establish the three-dimensional model of the rocker arm, and EDEM-ADAMS software was used to build the elevation working condition model of shearer cutting 4 types of gangue coal rocks, containing aluminous rock, gray rock, limestone and siltstone, to simulate the deformation of the rocker arm shell. Finally, the shell deformation test platform was set up, and the experiment of shearer cutting silt-containing gangue coal was carried out. The simulation results showed that the mean value of drag traction resistance was less than the mean value of cutting resistance, and both were greater than the mean value of lateral force. After the shell was subjected to external loads, its deformation was complex, at the joint of the rocker arm shell and the drum planetary reducer, the deformation was large, and the risk of instability was large. The deformation of rocker arm shell at the position of gear shaft exhibited a nonlinear, approximate normal distribution with multiple peaks. The experimental results showed that the closer to the drum planetary reducer, the greater the deformation, which was highly consistent with the simulation results. The research clearly shows the deformation law of the rocker arm shell under complex loads providing a robust theoretical support for the improved design of the rocker arm shell, and is helpful to optimize the shearer design scheme, reduce the shell failure risk, and effectively improve the reliability and stability of the shearer in actual production.

Key words： rocker arm shell EDEM simulation cutting load deformation law experimental test

Received: 18 September 2024 Published: 06 May 2025

CLC:

TD 42

Corresponding Authors: Xiaohan YU E-mail: qingyalou403@163.com;1060592986@qq.com

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Cite this article:

Liyong TIAN,Xiaohan YU,Ning YU. Study on deformation law of rocker arm shell of shearer based on EDEM-ADAMS. Chinese Journal of Engineering Design, 2025, 32(2): 220-231.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.04.169 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I2/220

基于EDEM-ADAMS的采煤机摇臂壳体变形规律研究

为了剖析采煤机摇臂壳体失效的根源、保障采煤机安全稳定运行，分析了采煤机摇臂壳体变形的影响因素，研究了壳体变形规律。首先，构建了摇臂壳体力学模型，梳理了影响摇臂壳体变形的载荷因素，其中包括采煤机截割时煤岩对滚筒产生的外部作用力及齿轮传动系统所形成的内部载荷；其次，采用Solidworks软件建立了摇臂三维模型，并基于EDEM-ADAMS软件搭建了采煤机截割含铝质岩、灰色岩、石灰岩和粉砾岩等4种夹矸煤岩的仰角工况模型，进行摇臂壳体变形仿真；最后，搭建了壳体变形测试平台，进行了采煤机截割粉砂夹矸煤岩的实验。仿真结果表明：滚筒牵引阻力的均值小于截割阻力均值，且两者均大于侧向受力均值；壳体承受外部载荷后，其变形呈现较复杂的态势，在摇臂壳体与滚筒行星减速器结合部位的变形较大，失稳风险较大；摇臂壳体在齿轮轴位置的变形呈现多波峰、非线性、近似正态分布。实验结果表明，距滚筒行星减速器越近，变形越大，这与仿真结果高度吻合。研究清晰地揭示了摇臂壳体在复杂载荷下的变形规律，为摇臂壳体的改进设计提供了强劲的理论支撑，有助于优化采煤机设计方案，降低壳体失效风险，有效提升采煤机在实际生产作业中的可靠性与稳定性。

关键词： 摇臂壳体, EDEM仿真, 截割载荷, 变形规律, 实验测试

Fig.1 Schematic of rocker arm shell force

Fig.2 Schematic of three-way force of drum

Fig.3 Gear force analysis

Fig.4 Schematic of structure of rocker arm transmission system

Table 1 Size parameters of gear of rocker arm transmission system

Fig.5 Model of rocker arm shell

Fig.6 Grid independence verification result of rocker arm shell model

Table 2 Parameters of gangue coal rock material

Table 3 Interaction parameters between materials

Table 4 Bonding parameters between coal rock particles

Fig.7 Topology diagram of constraint relationships of rocker arm transmission system

Table 5 constraint relationships between components

Fig.8 Simulation process of drum cutting gangue coal rock

Fig.9 Three-way cutting load and torque on drum

Fig.10 Comparison of mean value of three-way cutting load on drum and fluctuation coefficient under different working conditions

Fig.11 Three-dimensional diagram of rocker arm shell deformation

Fig.12 Deformation cloud diagram of rocker arm shell under working condition of aluminum rock gangue with cutting 18.2 s

Fig.13 Rocker arm shell deformation test platform

Table 6 Mass concentration of each material of simulated gangue coal rock

Fig.14 Schematic of primary positions of rocker arm shell strain sensor

Table 7 Setting of rocker arm shell strain measuring point after optimization

Fig.15 Arrangement of rocker arm shell strain sensor

Table 8 Data collected by strain sensor

Fig.16 Strain curves of measuring points in x direction

Fig.17 Strain curves of measuring points in y direction

Fig.18 Combined strain curves of measuring point 8, 9, 10


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