Assessment of pick wear based on the field performance of two transverse type roadheaders: a case study from Amasra coalfield

Abstract

A successful excavation of roadheaders depends on the cutting performance and the tool life of conical picks. Tool life is important in terms of wear rate which is affected by different rock parameters such as equivalent quartz content, mineral grain size, as well as cutting parameters on the cutterhead. In this study, analyses among wear rate, specific energy, advance rate, and cutter consumption were carried out. The wear mechanisms of two different models of conical picks were examined from different aspects depending on rock and machine parameters. Their relation with the mechanical and abrasivity properties of rocks and petrographic analyses were investigated. In addition, the metallurgic content and Rockwell hardness of conical picks were determined to describe the metal alloys and their effects on the wear of cutting tool. The results showed that the metallurgic content, pick positions, and other environmental conditions influence the wear mechanism. Finally, two different models were proposed to estimate the pick consumption in sandstone and siltstone rocks based on actual data obtained from coalfield.

This is a preview of subscription content, log in to check access.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

References

  1. Akkas M (2019) Assessment of performance and pick consumption of medium duty roadheaders driven in Amasra coalfield. Zonguldak Bulent Ecevit University

  2. Alber M et al (2013) ISRM suggested method for determining the abrasivity of rock by the CERCHAR abrasivity test. Rock Mech Rock Eng 47:261–266. https://doi.org/10.1007/s00603-013-0518-0

    Article  Google Scholar 

  3. Aydın H (2019) Investigating the effects of various testing parameters on Cerchar abrasivity index and its repeatability. Wear 418-419:61–74. https://doi.org/10.1016/j.wear.2018.11.001

    Article  Google Scholar 

  4. Balci C, Demircin MA, Copur H, Tuncdemir H (2004) Estimation of optimum specific energy based on rock properties for assessment of roadheader performance. J South Afr Inst Min Metall 104:633–641

    Google Scholar 

  5. Beste U, Jacobson S (2008) A new view of the deterioration and wear of WC/Co cemented carbide rock drill buttons. Wear 264:1129–1141. https://doi.org/10.1016/j.wear.2007.01.030

    Article  Google Scholar 

  6. Bilgin N, Dincer T, Copur H, Erdogan M (2004) Some geological and geotechnical factors affecting the performance of a roadheader in an inclined tunnel. Tunn Undergr Space Technol 19:629–636. https://doi.org/10.1016/j.tust.2004.04.004

    Article  Google Scholar 

  7. Bilgin N, Demircin MA, Copur H, Balci C, Tuncdemir H, Akcin N (2006) Dominant rock properties affecting the performance of conical picks and the comparison of some experimental and theoretical results. Int J Rock Mech Min Sci 43:139–156. https://doi.org/10.1016/j.ijrmms.2005.04.009

    Article  Google Scholar 

  8. Bilgin N, Copur H, Balci C (2014) Mechanical excavation in mining and civil industries. 1st edn. CRC Press, New York

    Google Scholar 

  9. Carbonell J, Onate E, Suarez B (2013) Modelling of tunnelling processes and rock cutting tool wear with the particle finite element method. Comput Mech 52:607–629. https://doi.org/10.1007/s00466-013-0835-x

    Article  Google Scholar 

  10. Comakli R (2019) Effects of the physico-mechanical properties of low-strength pyroclastic rocks on cutter wear of roadheaders. Wear 428-429:205–216. https://doi.org/10.1016/j.wear.2019.03.014

    Article  Google Scholar 

  11. Copur H, Ozdemir L, Rostami J (1998) Roadheader applicaitons in mining and tunneling projects. Min Eng 50:38–42

    Google Scholar 

  12. Deketh HJR (1995) Wear of rock cutting tools, laboratory experiments on the abrasivity of rock. Balkema, Rotterdam

    Google Scholar 

  13. Deketh HJR, Grima MA, Hergarden IM, Giezen M, Verhoef PNW (1998) Towards the prediction of rock excavation machine performance. Bull Eng Geol Environ 57:3–15. https://doi.org/10.1007/s100640050016

    Article  Google Scholar 

  14. Dewangan S, Chattopadhyaya S, Hloch S (2015) Wear assessment of conical pick used in coal cutting operation. Rock Mech Rock Eng 48:2129–2139. https://doi.org/10.1007/s00603-014-0680-z

    Article  Google Scholar 

  15. Dogruoz C, Bolukbasi N (2014) Effect of cutting tool blunting on the performances of various mechanical excavators used in low- and medium-strength rocks. Bull Eng Geol Environ 73:781–789. https://doi.org/10.1007/s10064-013-0551-y

    Article  Google Scholar 

  16. Dogruoz C, Rostami J, Keles S (2018) Study of correlation between specific energy of cutting and physical properties of rock and prediction of excavation rate for lignite mines in Cayirhan area, Turkey. Bull Eng Geol Environ 77:533–539. https://doi.org/10.1007/s10064-017-1124-2

    Article  Google Scholar 

  17. Frenzel C (2011) Disc cutter wear phenomenology and their implications on disc cutter consumption for TBM. Paper presented at the 45th US Rock Mechanics/Geomechanics Symposium

  18. Hassanpour J (2018) Development of an empirical model to estimate disc cutter wear for sedimentary and low to medium grade metamorphic rocks. Tunn Undergr Space Technol 75:90–99. https://doi.org/10.1016/j.tust.2018.02.009

    Article  Google Scholar 

  19. ISRM (1981) ISRM Commission on Testing Methods. Suggested methods of rock characterization, testing, and monitoring. Pergamon

  20. Jones HG, Norgren SM, Kritikos M, Mingard KP, Gee MG (2017) Examination of wear damage to rock-mining hardmetal drill bits. Int J Refract Met Hard Mater 66:1–10. https://doi.org/10.1016/j.ijrmhm.2017.01.013

    Article  Google Scholar 

  21. Karayigit AI, Gayer RA, Demirel IH (1998) Coal rank and petrography of Upper Carboniferous seams in the Amasra coalfield, Turkey. Int J Coal Geol 36:277–294. https://doi.org/10.1016/S0166-5162(97)00047-5

    Article  Google Scholar 

  22. Li FH, Cai ZX, Kang YL (2011) A theoretical model for estimating the wear of the disc cutter Advances in Civil Engineering, Pts 1-4 90–93:2232–2236 doi:https://doi.org/10.4028/www.scientific.net/AMM.90-93.2232

  23. Li X, Wang S, Wang S (2017) Experimental investigation of the influence of confining stress on hard rock fragmentation using a conical pick. Rock Mech Rock Eng 51:255–277. https://doi.org/10.1007/s00603-017-1309-9

    Article  Google Scholar 

  24. Li HS, Liu SY, Xu PP (2019) Numerical simulation on interaction stress analysis of rock with conical picks. Tunn Undergr Space Technol 85:231–242. https://doi.org/10.1016/j.tust.2018.12.014

    Article  Google Scholar 

  25. Liu S, Ji H, Liu X, Jiang H (2017) Experimental research on wear of conical pick interacting with coal-rock. Eng Fail Anal 74:172–187. https://doi.org/10.1016/j.engfailanal.2017.01.013

    Article  Google Scholar 

  26. Majeed Y, Abu Bakar MZ (2016) Statistical evaluation of CERCHAR abrasivity index (CAI) measurement methods and dependence on petrographic and mechanical properties of selected rocks of Pakistan. Bull Eng Geol Environ 75:1341–1360. https://doi.org/10.1007/s10064-015-0799-5

    Article  Google Scholar 

  27. McFeat S, Fowell RJ (1979) The selection and application of roadheaders for rock tunneling. Paper presented at the 4th Rapid Excavation and Tunneling Conference, Atlanta, USA

  28. Moradizadeh M, Cheshomi A, Ghafoori M, TrighAzali S (2016) Correlation of equivalent quartz content, Slake durability index and Is50 with Cerchar abrasiveness index for different types of rock. Int J Rock Mech Min Sci 86:42–47. https://doi.org/10.1016/j.ijrmms.2016.04.003

    Article  Google Scholar 

  29. Plinninger R, Käsling H, Thuro K, Spaun G (2003) Testing conditions and geomechanical properties influencing the CERCHAR abrasiveness index (CAI) value. Int J Rock Mech Min Sci 40:259–263. https://doi.org/10.1016/S1365-1609(02)00140-5

    Article  Google Scholar 

  30. Ren DJ, Shen SL, Arulrajah A, Cheng WC (2018) Prediction model of TBM disc cutter wear during tunnelling in heterogeneous ground. Rock Mech Rock Eng 51:3599–3611. https://doi.org/10.1007/s00603-018-1549-3

    Article  Google Scholar 

  31. Rojek J (2014) Discrete element thermomechanical modelling of rock cutting with valuation of tool wear. Comput Part Mech 1:71–84. https://doi.org/10.1007/s40571-014-0008-5

    Article  Google Scholar 

  32. Rojek J et al (2008) Prediction of wear of roadheader picks using numerical simulations. Geomech Tunn 1:47–54. https://doi.org/10.1002/geot.200800005

    Article  Google Scholar 

  33. Saeidi O, Elyasi A, Torabi SR (2015) Wear assessment of the WC/Co cemented carbide tricone drill bits in an open pit mine. Geomech Eng 8:477–493. https://doi.org/10.12989/gae.2015.8.4.477

    Article  Google Scholar 

  34. Schimazek T, Knatz H (1970) The influence of rock structure on the cutting speed and pick wear of heading machines. Glücckauf:275–278

  35. Singh SP, Chattopadhyaya S (2013) A review on the excavator tool bits wear. Paper presented at the 1st International and 16th National Conference on Machines and Mechanisms, IIT Roorkee, India, December, 18-20

  36. Sun Z et al (2019) A practical TBM cutter wear prediction model for disc cutter life and rock wear ability. Tunn Undergr Space Technol 85:92–99. https://doi.org/10.1016/j.tust.2018.12.010

    Article  Google Scholar 

  37. Thuro K, Plinninger RJ (2003) Hard rock tunnel boring, cutting, drilling and blasting: rock parameters for excavability. In: 10th ISRM Congress, South Africa

  38. Tkalich D et al (2017) Wear of cemented tungsten carbide percussive drill–bit inserts: laboratory and field study. Wear 386-387:106–117. https://doi.org/10.1016/j.wear.2017.05.010

    Article  Google Scholar 

  39. Trent EM (1969) The wear rate of carbide cutting tools. Powder Metall 12:566–581. https://doi.org/10.1179/pom.1969.12.24.019

    Article  Google Scholar 

  40. Wang S, Li X, Du K, Wang S, Tao M (2018) Experimental study of the triaxial strength properties of hollow cylindrical granite specimens under coupled external and internal confining stresses. Rock Mech Rock Eng 51:2015–2031. https://doi.org/10.1007/s00603-018-1452-y

    Article  Google Scholar 

  41. Wang S et al (2019) Experimental investigation of rock breakage by a conical pick and its application to non-explosive mechanized mining in deep hard rock. Int J Rock Mech Min Sci 122:104063. https://doi.org/10.1016/j.ijrmms.2019.104063

    Article  Google Scholar 

  42. Yaralı O, Duru H (2016) Investigation into effect of scratch length and surface condition on Cerchar abrasivity index. Tunn Undergr Space Technol 60:111–120. https://doi.org/10.1016/j.tust.2016.08.005

    Article  Google Scholar 

Download references

Acknowledgments

The authors would like to acknowledge the support from Scientific Research Project of Zonguldak Bulent Ecevit University for funding this research under Grant No. 2014-29011448-02.

Author information

Affiliations

Authors

Corresponding author

Correspondence to Okan Su.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Su, O., Akkaş, M. Assessment of pick wear based on the field performance of two transverse type roadheaders: a case study from Amasra coalfield. Bull Eng Geol Environ 79, 2499–2512 (2020). https://doi.org/10.1007/s10064-019-01712-x

Download citation

Keywords

  • Pick wear
  • Advance rate
  • Specific energy
  • Rock excavation
  • Conical pick
  • Roadheader