Installation Optimization Of Disc Cutter And Design Of Testing Machine Under Rotary Cutting Working Condition

Disc cutter as the main tool of TBM broken rock,installation method directly impact the load and the efficiency of excavation.Lateral load causes eccentric wear of the blade,the vertical load and the rolling load are closely related to specific energy consumption.In this paper,two aspects of disc cutter installation methods and test machine design are studied,respectively,the optimum installation angle of forward slanting and outward slanting installation are given,and a rock breaking test machine is designed to verify the installation theory.The research contents are as follows:(1)The rock breaking mechanism is analyzed,and the formula for predicting the rock breaking load and the specific energy consumption formula are summed.The rock breaking loads of the three kinds of installation methods are compared and analyzed according to the rock breaking mechanism and the load forecasting formula.(2)It has been completed the nonlinear rock breaking simulation of the disc cutter’s three kinds of installation methods by using HYPERMESH and ANSYS/LS-DYNA,The rock breaking load and specific energy of the traditional positive installation,forward slanting and outward slanting installation were comparatively analyzed by LS-PREPOST and MATLAB,respectively,best installation angle of forward slanting and outward slanting installation were determined,disc cutter installation optimization are completed.(3)According to the simulation results of the three installation methods of disc cutter and the calculation of the prediction formula,the load parameters of the test machine are given.Designing a rotary cutting rock testing machine which can meet the three installation methods of disc cutter,and using UG software for testing machine’s component modeling and assembly.(4)ANSYS software was used to analyze the mechanics of rotary cutting rock breaking test machine,including the entire testing machine static analysis,modal analysis and mechanical analysis of key components.The mechanical analysis of the test machine and key components is used to check the strength and stiffness.The modal analysis gives the natural frequency of the testing machine and the corresponding mode shapes so as to avoid the resonance of the testing machine during operation.Through the theoretical and simulation analysis of the three installation methods,we found that proper forward slanting installation can make the lateral load close to 0.This will prevent the blade from eccentric wear.Appropriate outward slanting installation can achieve the minimum specific energy rock breaking.And the structural design of the rotary cutting and breaking rock testing machine which used to verify disc cutter installation optimization is completed.