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<p>To address the challenges of severe wear and low rock-breaking efficiency in roller cutters used for shaft sinking by drilling methods in the Jurassic strata of western China, this study investigated a milled-tooth roller cutter, a commonly employed tool in these drilling methods, and examined its rock-breaking modes. Using a finite–discrete element method (FDEM) numerical simulation, a four-factor, four-level orthogonal experiment was conducted to evaluate the effects of penetration depth, cutter tooth length, row spacing, and tooth spacing on rock-breaking force, specific energy, and crack propagation index. Range and variance analyses identified the 5<sup>#</sup> roller cutter as the optimal tool based on the specific energy and crack propagation index as evaluation indicators. The analysis indicated that the rock-breaking mode of single-ring cutter teeth can be classified as either progressive or non-progressive, whereas that of single-row cutter teeth can be categorized as cooperative or non-cooperative. The numerical simulation results demonstrated Maximum errors of 7.05 and 6.72% for the average normal and rolling forces, respectively, and of 14.88 and 8.68% for the peak forces, respectively. Penetration depth, cutter tooth length, and row spacing significantly influenced the average forces, whereas penetration depth, tooth spacing, and cutter tooth length affected both the specific energy and the crack propagation index. Specific energy was positively correlated with cutter tooth length and tooth spacing but negatively correlated with row spacing, and it decreased initially before increasing with penetration depth. The crack propagation index displayed a pattern of variation opposite to that of the specific energy in relation to all factors. Compared with the field roller cutter, the 5<sup>#</sup> cutter achieved a larger rock-breaking area, reduced force requirements, improved efficiency, and enhanced performance. These findings provide theoretical guidance for optimizing milled-tooth roller cutter design for shaft sinking in Jurassic formations in Western China.</p>

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Optimization of Cutter Body Parameters for Milled-Tooth Roller Cutters in Shaft Sinking by Drilling Methods: A Case Study in Jurassic Strata of Western China

  • 期刊论文

  • 发表日期：

    2025年9月9日

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  • Xiaoyun Wang,
  • Hua Cheng,
  • Zhishu Yao,
  • Jian Lin,
  • Longhui Guo,
  • Liangliang Zhang

摘要

To address the challenges of severe wear and low rock-breaking efficiency in roller cutters used for shaft sinking by drilling methods in the Jurassic strata of western China, this study investigated a milled-tooth roller cutter, a commonly employed tool in these drilling methods, and examined its rock-breaking modes. Using a finite–discrete element method (FDEM) numerical simulation, a four-factor, four-level orthogonal experiment was conducted to evaluate the effects of penetration depth, cutter tooth length, row spacing, and tooth spacing on rock-breaking force, specific energy, and crack propagation index. Range and variance analyses identified the 5# roller cutter as the optimal tool based on the specific energy and crack propagation index as evaluation indicators. The analysis indicated that the rock-breaking mode of single-ring cutter teeth can be classified as either progressive or non-progressive, whereas that of single-row cutter teeth can be categorized as cooperative or non-cooperative. The numerical simulation results demonstrated Maximum errors of 7.05 and 6.72% for the average normal and rolling forces, respectively, and of 14.88 and 8.68% for the peak forces, respectively. Penetration depth, cutter tooth length, and row spacing significantly influenced the average forces, whereas penetration depth, tooth spacing, and cutter tooth length affected both the specific energy and the crack propagation index. Specific energy was positively correlated with cutter tooth length and tooth spacing but negatively correlated with row spacing, and it decreased initially before increasing with penetration depth. The crack propagation index displayed a pattern of variation opposite to that of the specific energy in relation to all factors. Compared with the field roller cutter, the 5# cutter achieved a larger rock-breaking area, reduced force requirements, improved efficiency, and enhanced performance. These findings provide theoretical guidance for optimizing milled-tooth roller cutter design for shaft sinking in Jurassic formations in Western China.