截割间距对镐型截齿破岩特性影响的试验研究

刘滨; 李雪峰

doi:10.13272/j.issn.1671-251x.2022120046

截割间距对镐型截齿破岩特性影响的试验研究

doi: 10.13272/j.issn.1671-251x.2022120046

刘滨,
李雪峰^,

南京工业职业技术大学机械工程学院, 江苏南京　210023

基金项目: 国家自然科学基金面上项目（51874279）；江苏省高校自然科学研究面上项目（20KJB440005）；南京工业职业技术大学引进人才科研启动基金项目（YK21-01-04）。

详细信息

作者简介:
刘滨(1964—)，男，黑龙江哈尔滨人，副教授，主要研究方向为航空发动机设计、矿山机械，E-mail：1317236488@qq.com

通讯作者:
李雪峰(1990—)，男，江苏沛县人，讲师，博士，主要研究方向为深部煤层开采、矿山机械，E-mail：leexf2009@163.com

中图分类号: TD421.5
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出版历程
- 收稿日期: 2022-12-15
- 修回日期: 2023-07-20
- 网络出版日期: 2023-09-04

Experimental study on the influence of cutting distance on the rock-breaking features of pick-shaped cutter

LIU Bin,
LI Xuefeng^,

College of Mechanical Engineering, Nanjing Vocational University of Industry Technology, Nanjing 210023, China

摘要

摘要: 镐型截齿是掘进机、采煤机等矿山机械上应用最广泛的截齿类型。在实际截割过程中，镐型截齿主要工作于多齿耦合截割工况下，截割间距是该工况下的重要参数。针对截割间距对破岩过程影响的研究未考虑干涉截割的弱化作用的问题，提出一种多齿耦合截割时截割力的计算方法。针对石灰岩、红砂岩和2种模拟岩样开展了全尺寸单齿截割试验，对比分析自由截割和干涉截割的破岩过程。试验采集了截割力数据并进行了降噪处理，同时收集了截割碎屑，分析了截割间距对截割载荷、截割碎屑粒度、截割能耗、截割沟槽的影响规律。试验结果表明：① 截齿截割力随截割间距增加而增大，并逐渐接近自由截割状态，且干涉截割与自由截割条件下的截割力比值与截割间距/截割深度之间存在较好的线性关系，相关系数均大于0.95。说明干涉截割条件下截齿的截割载荷可利用自由截割载荷进行估算，进而得到了基于已有峰值截割力模型的干涉截割条件下的截割力估算方程。② 分别采用碎屑粒度指数(CI)和截割比能耗(SE)评价截割试验的碎屑粒度分布和截割能耗。随截割间距增大，CI呈先增大后减小的趋势，而SE呈先减小后增大的趋势。③ 当截割间距较小时，截割沟槽干涉显著，截割沟槽间残余岩脊较小，截割载荷较小，但由于截割沟槽干涉会产生较多细小碎屑，消耗较多能量，所以能耗升高；随着截割间距增大，残余岩脊增大，截割力增大，但由于已有截割沟槽对岩石的弱化作用且截割沟槽间干涉较少，形成的大块碎屑占比增大，所以截割能耗降低；随着截割间距进一步增大，截割沟槽间无干涉，且已有截割沟槽对岩石的弱化作用降低，截割力增大，碎屑粒度减小，截割能耗上升，截割状态逐渐趋近于自由截割。
- 螺旋滚筒 /
- 煤岩截割 /
- 镐型截齿 /
- 截割间距 /
- 干涉截割 /
- 自由截割 /
- 截割沟槽 /
- 截割深度
Abstract: The pick-shaped cutter is the most widely used cutter type in mining machinery such as roadheader and coal mining machine. In the actual cutting process, the pick-shaped cutter mainly works under the multi-tooth coupling cutting condition. The cutting distance is an important parameter under this working condition. At present, research on the influence of cutting spacing on the rock-breaking process has not considered the weakening effect of interference cutting. A calculation method for cutting force during multi-tooth coupling cutting is proposed to solve the above problem. Full-size single-tooth cutting tests are carried out on limestone, red sandstone and two simulated rock samples, comparing and analyzing the rock-breaking processes of free cutting and interference cutting. The experiment collects cutting force data and conducts noise reduction processing and collects cutting debris to analyze the impact law of cutting spacing on cutting load, cutting debris coarseness, cutting energy consumption, and cutting grooves. The experimental results show the following points. ① The cutting force of the cutter increases with the increase of cutting distance and gradually approaches the free cutting state. Moreover, there is a good linear relationship between the cutting force ratio under interference cutting and free cutting conditions and the cutting distance/cutting depth. The correlation coefficients are greater than 0.95. The cutting load of the cutter under interference cutting conditions can be estimated using the free cutting load. The cutting force estimation equation under interference cutting conditions based on the existing peak cutting force model is obtained. ② The coarseness index (CI) and specific energy (SE) are used respectively to evaluate the particle size distribution and cutting energy consumption of the cutting experiment. As the cutting distance increases, CI shows a trend of first increasing and then decreasing. SE shows a trend of first decreasing and then increasing. ③ When the cutting distance is small, the interference between the cutting grooves is significant, the residual rock ridges between the cutting grooves are small, and the cutting load is small. However, due to the interference between the cutting grooves, more small debris is generated. It consumes more energy and increases energy consumption. As the cutting distance increases, the residual rock ridge increases, and the cutting force increases. However, due to the weakening effect of existing cutting grooves on the rock and less interference between cutting grooves, the proportion of large debris formed increases, and the cutting energy consumption decreases. As the cutting distance further increases, there is no interference between the cutting grooves. The weakening effect of the existing cutting grooves on the rock decreases. The cutting force increases, the coarseness decreases, and the cutting energy consumption increases. The cutting state gradually approaches free cutting.
- spiral drum /
- coal rock cutting /
- pick-shaped cutter /
- cutting distance /
- interference cutting /
- free cutting /
- cutting grooves /
- cutting depth

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图 1 全尺寸岩石线性截割试验机

Figure 1. Full-scale rock linear cutting tester

下载: 全尺寸图片幻灯片

图 2 全尺寸岩石线性截割试验机测控原理

Figure 2. Measurement and control principle of full-scale rock linear cutting tester

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图 3 截齿三向力

Figure 3. Cutter three-way force

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图 4 多齿截割试验方案

Figure 4. Multi-cutter cutting test protocol

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图 5 截割试验所用岩石试样

Figure 5. Rock samples used in cutting tests

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图 6 截割三向力（降噪前）

Figure 6. Cutting three-way force (before noise reduction)

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图 7 截割力数据EMD分解结果

Figure 7. EMD decomposition results of cutting force data

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图 8 截割三向力（降噪后）

Figure 8. Cutting three-way force (after noise reduction)

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图 9 截割力均值随截割间距的变化

Figure 9. Change of mean cutting force with cutting distance

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图 10 截割载荷比值f_r随s/d的变化关系

Figure 10. Relationships between the mean cutting loade ratio f_r and s/d

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图 11 干涉与自由截割力比值随s/d的变化趋势

Figure 11. The trend of the ratio of interference and free cutting force with s/d

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图 12 不同截割间距下截割碎屑粒度筛分

Figure 12. Coarseness at different cutting distance

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图 13 截割间距与CI、SE的关系曲线

Figure 13. The relationships between cutting distance and CI and SE

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图 14 不同截割间距下的截割沟槽

Figure 14. Cutting grooves with different cutting distrance

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图 15 截割间距对截割沟槽干涉情况的影响

Figure 15. Effect of cutting distance on cutting grooves

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表 1 岩样物理力学特性

Table 1. Properties of rock samples

岩石类型	单轴抗压强度/MPa	抗拉强度/MPa	弹性模量/GPa	泊松比	密度/ （kg·m⁻³）
石灰岩	116.4	8.2	46.3	0.32	2650
红砂岩	76.3	6.6	22.4	0.19	2140
模拟岩样 I	13.3	1.12	12.1	0.23	1390
模拟岩样 II	18.0	1.65	15.3	0.24	1660

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表 2 截割间距及截割深度参数设置

Table 2. Parameter setting of cuting distancet and cutting depth

岩石类型	d/mm	s/d
石灰岩	2, 3, 4, 5	1~10
红砂岩	5, 10	2~6
模拟岩样I	5, 10, 15, 20	1~7
模拟岩样 II	5, 10, 15	1~10

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表 3 干涉截割时截割三向力均值

Table 3. Mean cutting three-way force in interference cutting tests

s/mm	F_X／kN	F_Y／kN	F_Z／kN
自由	7.61	1.21	9.57
20	3.10	−2.05	5.55
30	3.61	−1.41	6.04
40	4.32	−1.45	6.54
50	5.63	−1.49	7.46
60	5.95	−0.72	7.82
70	6.34	−0.65	8.14

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表 4 各岩样不同截割参数下截割力比值f_r

Table 4. Cutting force ratios f_r under different cutting conditions

石灰岩			红砂岩			模拟岩样I			模拟岩样II
d	s/d	f_r	d	s/d	f_r	d	s/d	f_r	d	s/d	f_r
2	1	0.43	5	2	0.60	5	2	0.24	5	2	0.50
	3	0.63		3	0.70		3	0.68		4	0.76
	5	0.58		4	0.73		4	0.56		6	0.91
	7	0.70		5	0.82		6	0.85		8	0.83
	10	0.89		6	0.81		7	1.04		10	1.01
3	1	0.43	10	2	0.54	10	1	0.21	10	2	0.46
	3	0.55		3	0.78		2	0.38		3	0.60
	5	0.62		5	0.75		2.5	0.41		4	0.72
	7	0.81		6	1.00		3	0.44		5	0.79
	10	0.99					4	0.47		6	0.88
							5	0.65
4	1	0.51				15	1	0.39	15	1.33	0.41
	3	0.68					2	0.42		2	0.47
	5	0.88					3	0.65		2.67	0.57
	7	0.92					4	0.86		3.33	0.74
	10	1.01								4	0.78
										4.67	0.83
5	1	0.53				20	1	0.41
	3	0.63					1.5	0.51
	5	0.85					2	0.56
	7	0.96					2.5	0.57
	10	0.96					3	0.75
							3.5	0.87

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表 5 截割碎屑粒度分布及CI和SE汇总

Table 5. Summary coarseness distribution and CI and SE

截割间距/mm	不同截割间距下碎屑粒度占比/%							CI	总质量/g	SE/(MJ·m⁻³)
截割间距/mm	＞25 mm	＞15 mm	＞10 mm	＞5 mm	＞3.2 mm	＞1.43 mm	＞0	CI	总质量/g	SE/(MJ·m⁻³)
自由	47.4	62	68.7	78.8	83.0	88.0	100	528	940	10.4
20	20.7	44	55.3	68.5	75.5	82.3	100	446	309	13.3
30	38.1	57.1	66.4	76.7	81.9	87.4	100	508	641	7.5
40	53.4	67.5	73.7	82.9	87.2	91.1	100	556	944	6.1
50	53.6	67	75.5	84.1	87.6	91.4	100	559	1 253	6.0
60	52.9	67.6	74.8	84.3	88.3	92	100	560	984	8.0
70	49.7	63.3	70.5	80.6	85.1	89.4	100	539	886	9.5

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