Prediction of Wear of Roadheader Picks Using Numerical Simulations

The paper presents prediction of wear of roadheader picks using numerical simulations. Estimation of wear has been included into the numerical model of rock cutting based on the discrete element method. The amount of wear is calculated using the classical formula of Archard. The wear model takes the influence of temperature by considering the hardness of the worn material as temperature dependent into account. The set of parameters for the discrete element model has been established by a calibration procedure based on numerical simulation of the unconfined compression and Brazilian tests, with the results of laboratory tests as reference data. After having established model parameters, numerical simulation of cutting process with a roadheader pick has been carried out. The simulation provides values and variation of cutting forces. Temperature increase due to frictional heat is obtained in the thermo-mechanical simulation of cutting. Numerical analysis yields the wear profile as well as the tool shape evolution due to wear. The numerical model developed allows studying the wear intensity for different cutting process parameters. The developed method can be employed in the design of cutting heads and cutting operations in underground excavations with roadheaders.