Simulation analysis of the influence of gangue layer morphology on the cutting characteristics of the roadheader bolter
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摘要: 巷道实际掘进过程中掘进工作面除全煤层外还有各种矸石层，矸石层的存在会影响掘锚机掘进效率。然而目前大多以全煤层工作面为研究背景对滚筒截割特性进行分析，或考虑的矸石层形态较为单一。针对上述问题，以MB670−1型掘锚机为研究对象，利用Pro/E软件绘制掘锚机三维模型，将模型导入RecurDyn软件并添加相应的运动副，之后再导入EDEM软件，建立EDEM−RecurDyn耦合仿真模型。从滚筒截割性能、滚筒位移和滚筒振动3个方面仿真分析了水平矸石层、斜矸石层、半矸石层3种矸石层形态对掘锚机截割特性的影响，结果表明：① 与全煤层相比，在矸石层条件下滚筒截割阻力、载荷波动系数、截割比能耗均有所增加，尤其在斜矸石层条件下增加最明显，截割阻力均值增大了35.61%，X轴（沿掘锚机掘进方向）、Y轴（垂直于巷道底板方向）、Z轴（与滚筒轴平行方向）载荷波动系数分别增大了26.79%，25.39%，61.28%，截割比能耗增大了37.21%。② 矸石层的存在使滚筒位移有所减小，相比于全煤层，在水平矸石层、斜矸石层、半矸石层条件下滚筒位移分别缩短了53，89，14 mm。③ 滚筒在截割含矸石层工作面时产生的振动幅度远大于截割全煤层工作面时。④ 矸石层形态对掘锚机截割特性的影响程度为斜矸石层>水平矸石层>半矸石层。Abstract: In the actual excavation process of the roadway, besides the coal seam, there are various types of gangue layers on the working face. The existence of these gangue layers will affect the cutting efficiency of the roadheader bolter. However, most current studies analyze the cutting characteristics of the drum with the background of a fully-coal working face or consider a relatively simple morphology of the gangue layer. To solve the above problems, taking the MB670-1 roadheader bolter as the research object, a 3D model of the roadheader bolter is created using Pro/E software. The model is input into RecurDyn software and the corresponding motion pair is added. The model is then input into EDEM software to establish an EDEM-RecurDyn coupling simulation model. The influence of three types of gangue layers, horizontal gangue layers, inclined gangue layers, and semi-gangue layers, on the cutting characteristics of the roadheader bolter is simulated and analyzed from three aspects: drum cutting performance, drum displacement and drum vibration. The results show the following points. ① Compared with the full coal seam, under the conditions of gangue layers, the drum cutting resistance, load fluctuation coefficient, and cutting specific energy consumption all increase. They increase most significantly under the condition of inclined rock layers. The average cutting resistance increases by 35.61%. The load fluctuation coefficients along the X-axis (along excavation direction of the roadheader bolter), Y-axis (perpendicular to the roadway bottom direction), and Z-axis (parallel to the drum axis direction) increase by 26.79%, 25.39%, and 61.28% respectively. The cutting specific energy consumption increases by 37.21%. ② The existence of gangue layers causes a decrease in the displacement of the drum. Compared with the full-coal seam, the displacement of the drum is reduced by 53, 89, 14 mm in the horizontal gangue layer, inclined gangue layer, and gangue layer respectively. ③ The vibration amplitude generated by the drum when cutting a working face containing gangue is much greater than when cutting a working face containing full-coal seams. ④ The influence of the morphology of the gangue layer on the cutting characteristics of the roadheader bolter is in the order of inclined gangue layer ＞ horizontal gangue layer ＞ semi-gangue layer.
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图 7 不同形态矸石层下滚筒所受截割阻力曲线
Figure 7. Cutting resistance curves of drum under different gangue layers
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图 9 不同形态矸石层下滚筒加速度变化曲线
Figure 9. Drum acceleration variation curves under different gangue layers
表 1 煤岩材料参数
Table 1 Material parameters of coal and rock
材料 密度/（kg·m−3） 泊松比 剪切模量/Pa 煤 1 420 0.32 1.9×108 矸石 2 350 0.10 1.2×109 
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表 2 掘锚机材料参数
Table 2 Material parameters of roadheader bolter
名称 材料 密度/（kg·m−3） 泊松比 剪切模量/Pa 截齿 42CrMo 7 800 0.3 8.2×1010 筒毂 16Mn 7 800 0.3 8.4×1010 其余部分 合金钢 7 800 0.3 7.0×1010
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表 3 接触参数
Table 3 Contact parameters
颗粒−颗粒 恢复因数 静摩擦因数 动摩擦因数 煤−煤 0.5 0.6 0.05 煤−矸石 0.5 0.7 0.08 煤−滚筒 0.5 0.4 0.05 矸石−矸石 0.6 0.8 0.10 矸石−滚筒 0.6 0.5 0.07
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表 4 颗粒粘结参数
Table 4 Particle bonding parameters
颗粒−颗粒 单位面积法
向刚度/（N·m−3）单位面积切
向刚度/（N·m−3）法向应力/
Pa切向应力/
Pa煤−煤 6.0×108 1.8×109 4.0×104 6.0×105 煤−矸石 1.0×109 2.4×109 6.8×104 8.0×106 矸石−矸石 2.8×109 2.7×109 1.9×105 9.0×106
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表 5 不同形态矸石层参数
Table 5 Parameters of different gangue layer
矸石层形态 箱体尺寸/m 箱体体积/m³ 矸石颗粒数量/个 长 宽 高 水平矸石层 5.50 1.5 0.3 2.475 18 954 斜矸石层 5.50 1.5 0.3 19 026 半矸石层 2.75 1.5 0.6 19 105
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表 6 不同形态矸石层下滚筒截割阻力均值
Table 6 Mean cutting resistance of drum under different gangue layers
矸石层形态 截割阻力均值/N 截割阻力均值增长率/% 全煤层 6.74×104 — 水平矸石层 8.93×104 32.49 斜矸石层 9.14×104 35.61 半矸石层 8.48×104 25.82
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表 7 不同矸石层形态下滚筒载荷波动系数
Table 7 Drum load fluctuation coefficient under different gangue layers
矸石层形态 方向 载荷均值/N 载荷波动系数 载荷波动系数增长率/% 全煤层 X轴 −9.46×104 0.56 — Y轴 6.74×104 0.63 — Z轴 3.19×103 4.52 — 水平矸石层 X轴 −1.24×104 0.58 3.57 Y轴 8.93×104 0.68 7.94 Z轴 5.14×103 5.46 20.79 斜矸石层 X轴 −1.49×104 0.71 26.79 Y轴 9.14×104 0.79 25.39 Z轴 3.56×103 7.29 61.28 半矸石层 X轴 −1.17×105 0.57 1.79 Y轴 8.48×104 0.66 4.76 Z轴 7.58×103 4.80 6.19
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表 8 不同形态矸石层下滚筒截割比能耗
Table 8 Specific cutting energy consumption of drum under different gangue layers
矸石层形态 截割比能耗/（kW·h·m−3） 截割比能耗增长率/% 全煤层 3.01 — 水平矸石层 3.45 14.62 斜矸石层 4.13 37.21 半矸石层 3.15 4.65
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