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<p>To address the challenge of accurately predicting the cutting force of milling cutter heads in underwater reef excavation engineering, a single-pick rotational cutting force model based on Evans' cutting theory is developed. A time-varying function for cutting thickness, induced by rotation–swing coupling, is introduced and experimentally validated. Building on this, a mean cutting force prediction model for multi-pick milling cutter heads is established by integrating swing kinematics and cutter spatial arrangement parameters. A uniform distribution assumption–integral superposition approach is employed in this model, which is verified through full-scale 3DEC discrete element numerical simulations and laboratory tests. Subsequently, 20 sets of parameter analyses are conducted to investigate the effects of reef-cutting parameters (cutting depth, swing velocity, rotational velocity). It is demonstrated that there is strong agreement between predicted and simulated cutting force time-history curves for the single-pick model. The multi-pick model predicts mean cutting forces with less than 9.8% deviation from simulations, significantly outperforming the traditional Evans model. It is revealed that mean cutting force increases with rising cutting depth and swing velocity but decreases gradually with higher rotational velocity, with cutting depth exerting a more pronounced influence. Conversely, the cutting force fluctuation coefficient decreases with greater cutting depth and swing velocity while increasing with rotational velocity. Cutting forces are effectively predicted by the proposed model, offering theoretical guidance for optimizing excavation parameters and force prediction in ecologically sensitive zones, thereby holding substantial engineering application value.</p>

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Mean Cutting Force Model for Multi-pick Milling Heads Based on Enhanced Evans Theory with Discrete Element Validation

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Deying Tang,
  • Erdi Abi,
  • Qifu Zeng,
  • Yibo Wu,
  • Qiumeng Yuan,
  • Zhiyi Zeng,
  • Xiao Han,
  • Mingjing Jiang

摘要

To address the challenge of accurately predicting the cutting force of milling cutter heads in underwater reef excavation engineering, a single-pick rotational cutting force model based on Evans' cutting theory is developed. A time-varying function for cutting thickness, induced by rotation–swing coupling, is introduced and experimentally validated. Building on this, a mean cutting force prediction model for multi-pick milling cutter heads is established by integrating swing kinematics and cutter spatial arrangement parameters. A uniform distribution assumption–integral superposition approach is employed in this model, which is verified through full-scale 3DEC discrete element numerical simulations and laboratory tests. Subsequently, 20 sets of parameter analyses are conducted to investigate the effects of reef-cutting parameters (cutting depth, swing velocity, rotational velocity). It is demonstrated that there is strong agreement between predicted and simulated cutting force time-history curves for the single-pick model. The multi-pick model predicts mean cutting forces with less than 9.8% deviation from simulations, significantly outperforming the traditional Evans model. It is revealed that mean cutting force increases with rising cutting depth and swing velocity but decreases gradually with higher rotational velocity, with cutting depth exerting a more pronounced influence. Conversely, the cutting force fluctuation coefficient decreases with greater cutting depth and swing velocity while increasing with rotational velocity. Cutting forces are effectively predicted by the proposed model, offering theoretical guidance for optimizing excavation parameters and force prediction in ecologically sensitive zones, thereby holding substantial engineering application value.