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<p>During coal mining processes, the mechanical roller used for cutting encounters various materials, including coal walls with diverse properties. This study demonstrated an approach that can reflect actual operational conditions highly accurately. To calibrate the discrete-element coal particle bond model, a methodology that integrates experimental and simulation techniques was adopted in this work. The model was verified by comparison with experimental results to develop a relatively accurate interception model. Unlike traditional discrete element interception models, which have limited capacity to intercept a large volume of single-particle pulverized coal, this model can generate a range of coal lumps-pulverized coal, small lumps, and large lumps-during the cutting process. The model was utilized to assess drum loading, coal-breaking efficiency, and lump coal rate. When transitioning from hard to soft coal, cutting torque decreases linearly from 100 to 500&#xa0;Nm. Compared to the considerably small torques observed when cutting soft rock, the fluctuations in torque within the cutting drum of the model were significantly reduced. The maximum differences in torque were 2188.241, 1950.913, and 1033.902&#xa0;Nm, respectively. Soft coal with the highest number of intercepted coal particles had an 8.89% higher total particle count than soft rock with the lowest number of intercepted particles. A vibrating screen test designed in EDEM to measure the intercepted lump coal rate&#xa0;showed that the overall lump coal rate decreased with diminishing coal rock strength. The lump coal rate for soft rock reached 34.98%, whereas that for hard to medium-soft coals were 30%–32%. Additionally, the loading rates for hard, medium, and medium-soft coals were similar: the lump coal rate for soft coal decreased to 27.91%. During the drum cutting simulation, medium, medium-soft, and soft coals produced upper flake gang with a false top. Medium-soft and soft coals formed a flake gang at the center of the coal wall. Torque curves corresponding to coal-wall gang formation revealed a consistent pattern: each curve exhibits a series of consecutive torque peaks followed by a sharp decline. These findings provide significant theoretical foundations and a simulation tool for optimizing shearer design, selecting cutting parameters, predicting coal wall stability, and controlling coal quality.</p>

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Study on drum cutting characteristics of artificial coal wall with varying dust-to-cement ratios

  • 期刊论文

  • 发表日期：

    2025年8月8日

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  • Jie Ren,
  • Wangtao Li,
  • Xuewen Wang,
  • Juanli Li,
  • Bo Li,
  • Rui Xia

摘要

During coal mining processes, the mechanical roller used for cutting encounters various materials, including coal walls with diverse properties. This study demonstrated an approach that can reflect actual operational conditions highly accurately. To calibrate the discrete-element coal particle bond model, a methodology that integrates experimental and simulation techniques was adopted in this work. The model was verified by comparison with experimental results to develop a relatively accurate interception model. Unlike traditional discrete element interception models, which have limited capacity to intercept a large volume of single-particle pulverized coal, this model can generate a range of coal lumps-pulverized coal, small lumps, and large lumps-during the cutting process. The model was utilized to assess drum loading, coal-breaking efficiency, and lump coal rate. When transitioning from hard to soft coal, cutting torque decreases linearly from 100 to 500 Nm. Compared to the considerably small torques observed when cutting soft rock, the fluctuations in torque within the cutting drum of the model were significantly reduced. The maximum differences in torque were 2188.241, 1950.913, and 1033.902 Nm, respectively. Soft coal with the highest number of intercepted coal particles had an 8.89% higher total particle count than soft rock with the lowest number of intercepted particles. A vibrating screen test designed in EDEM to measure the intercepted lump coal rate showed that the overall lump coal rate decreased with diminishing coal rock strength. The lump coal rate for soft rock reached 34.98%, whereas that for hard to medium-soft coals were 30%–32%. Additionally, the loading rates for hard, medium, and medium-soft coals were similar: the lump coal rate for soft coal decreased to 27.91%. During the drum cutting simulation, medium, medium-soft, and soft coals produced upper flake gang with a false top. Medium-soft and soft coals formed a flake gang at the center of the coal wall. Torque curves corresponding to coal-wall gang formation revealed a consistent pattern: each curve exhibits a series of consecutive torque peaks followed by a sharp decline. These findings provide significant theoretical foundations and a simulation tool for optimizing shearer design, selecting cutting parameters, predicting coal wall stability, and controlling coal quality.