Design And Research Of Cutting Reducer For Cantilever Roadheader

The cantilever roadheader is the main equipment for coal mining and roadway excavation.According to the arrangement of the cutting head,it is divided into two types:vertical axis and horizontal axis.The cutting mechanism of the cantilever roadheader is a working mechanism for cutting coal and rock.It mainly consists of a cutting motor,a cutting reducer,a working arm and a cutting head.When the cantilever roadheader performs coal roadway or soft rock roadway excavation,the coal or semi-coal rock can be cut by a fixedly mounted pick on the cutting head.The cutting reducer is a key component of the cutting mechanism of the roadheader.Its function is to transmit the motion and power of the cutting motor to the cutting head.It has a large gear ratio.When designing the cutting reducer,the transmission accuracy and strength requirements must be achieved,and the volume of the reducer should be as small as possible and compact.The power source of the cutting reducer is the cutting motor.The output power of the cutting motor is decelerated and twisted through the gear transmission.A bevel gear-cylindrical gear-planetary gear train is adopted by the gear transmission part to achieve a larger transmission ratio.The structure and transmission process of a certain type of cutting reducer are introduced.The design parameters of the cutting reducer is determined.The planetary gear train of the cutting reducer is optimized for minimum volume by Matlab software,which saved materials and reduced the cost.The SolidWorks software is used to establish a three-dimensional assembly model of the transmission part of the cutting reducer.The virtual prototype model of the gear transmission part is established by using ADAMS software.Through kinematic analysis of the gear transmission part,the curves of angular velocity of the gear is obtained.Compared the simulation value with the theoretical value,results meet application needs.Using the impact function method to calculate the contact force,the gear contact force curve is obtained by dynamic simulation analysis of the fixed load,drilling and cross-cutting conditions of the cutting reducer.The change in gear contact force was analyzed.The elastohydrodynamic lubrication analysis model of the gear transmission is established.The dimensionless and discrete processing of the basic equation of gear elastohydrodynamic lubrication is carried out.The lubrication state of the gear meshing process is obtained by numerical calculation.The oil film pressure and oil film thickness at several key points during the meshing process were analyzed.The planetary gear train,the planetary carrier and the inner ring gear of the transmission system was carried out by ANSYS Workbench.The stress,strain and total deformation could be known from the equivalent cloud map.By comparing the equivalent maximum stress value with the allowable stress value of the material,the strength met the requirements.The oil pressure is applied to the different meshing points of the sun gear teeth to obtain the gear tooth stress value.The gear tooth stress value is closer to the gear tooth stress value of the gear under working condition,and the strength check is more reliable.Low-order natural frequencies and modes are obtained by modal analysis of the planet carrier.The structural optimization design and size optimization design of the planet carrier and the inner ring gear are respectively carried out.The optimization results still meet the requirements.The optimization goal and lightweight design of the structure is achieved.In this paper,a relatively complete research method is formed through the design,calibration and simulation analysis of the cutting reducer.This method can improve the working performance of the cutting reducer,and has certain reference value for the design and research of the cantilever roadheader cutting reducer in the future.