EBZ45型掘进机截割头参数改进设计及动态仿真分析
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摘要
悬臂式纵轴掘进机是目前机械化掘进工作面的重要设备,广泛应用于隧道施工、铁路和公路的桥涵,以及矿井巷道施工等。而截割机构是掘进机直接进行煤岩截割的工作机构,消耗整机的大部分功率。减速机设计在保证达到传动精度和强度要求的同时,也要保证体积小、结构紧凑；截割机构的截割头参数较多,这些参数相互关联、影响和制约,有些与煤岩性质参数也有重要的关联,在设计中要综合考虑,使得这些参数之间相互匹配,这些参数匹配的好坏决定了掘进机的截割性能,截割性能对整机的工作效率、可靠性和使用寿命和截割的经济效益都有直接的影响,是整机性能的综合体现。本文从岩石破碎学、采煤机设计理论对EBZ45型悬臂式掘进机减速机进行设计,对截割头截齿安装参数、截齿焊接工装进行设计,并对截齿截割煤岩性能进行了必要的分析讨论。
针对EBZ45型掘进机问题较多的原减速机结构不足进行分析,并重新进行改造设计,改造后的减速机具有良好的均载浮动效果,提高了轴承寿命。
研究了截齿在截割头上的分布方法,提出了一种综合考虑截割头轮廓、煤岩参数、工况参数、最佳截线间距的等螺距升角螺旋线布齿方法,并应用于EBZ45型掘进机的布齿改进。
研制了一种新的截齿焊接工装,实现了齿座在截割头上的准确定位和连接,保证了截割头的制造质量。
利用有限元软件,建立截齿截割煤岩有限元模型,研究最佳切削角和截割厚度与截割比能耗的关系,为掘进机截割煤岩参数设计以及截齿截割煤岩的非线性动力学研究提供了理论依据。
Longitudinal-axis tunneling machine is an important device widely used in mechanized driving such as tunnel, railways, highway culvert construction and mine tunneling.And the cutting mechanism which directly taking part in rock cutting is consuming most of the machine's power. The design of the reducer must meet the requirements of transmission accuracy and intensity standard, also guarantee small in volume and tight in structure; there are a lot of parameters on cutting head while most of them are influencing and constriction each other, some are related to coal properties, In the design of cutting head we must take an overall consideration of the parameters matching that we can achieve high efficiency, high reliability and longer service life. Based on the theory of rock fragmentation and the method of the coal winning machinery design to design the longitudinal-axis tunneling machine EBZ45, including the improvement of the machine reducer, designing the parameters of the pick arrangement of the cutting header and the welding fixtures of the picks, finally, studying the property of the pick cutting the rock.
Have a research of the tunneling machine EBZ45, designed and made improvement of the reducer which had a lot of problems because of the irrational in the structure, the redesigned reducer shows to have good effect of having uniformly distributed load and improves the service life of the bearings.
Have a research of the arrangement of the picks in the tunneling machine EBZ45, put forward an equal-rise-angle spiral lines to distribute the picks, considering the contour of the cutting head, the characters of the coal, the excavating conditions and the optimal line spacing, and the method is applied to improve the arrangement of the picks in the tunneling machine EBZ45.
Developed a new welding fixtures of the picks at the foundation of the installing angles and the arrangement of the picks which can quickly and accurately locate the pick on the cutting head
Build a finite element model for the pick cutting rock was discussed with the finite element software, The influences of resistance on different cutting angel and the relations between cutting thickness and cutting energy consumption in different cutting angel were discussed, the whole result provides a new way in the field of dynamic modeling and simulation for pick cutting rock
针对EBZ45型掘进机问题较多的原减速机结构不足进行分析,并重新进行改造设计,改造后的减速机具有良好的均载浮动效果,提高了轴承寿命。
研究了截齿在截割头上的分布方法,提出了一种综合考虑截割头轮廓、煤岩参数、工况参数、最佳截线间距的等螺距升角螺旋线布齿方法,并应用于EBZ45型掘进机的布齿改进。
研制了一种新的截齿焊接工装,实现了齿座在截割头上的准确定位和连接,保证了截割头的制造质量。
利用有限元软件,建立截齿截割煤岩有限元模型,研究最佳切削角和截割厚度与截割比能耗的关系,为掘进机截割煤岩参数设计以及截齿截割煤岩的非线性动力学研究提供了理论依据。
Longitudinal-axis tunneling machine is an important device widely used in mechanized driving such as tunnel, railways, highway culvert construction and mine tunneling.And the cutting mechanism which directly taking part in rock cutting is consuming most of the machine's power. The design of the reducer must meet the requirements of transmission accuracy and intensity standard, also guarantee small in volume and tight in structure; there are a lot of parameters on cutting head while most of them are influencing and constriction each other, some are related to coal properties, In the design of cutting head we must take an overall consideration of the parameters matching that we can achieve high efficiency, high reliability and longer service life. Based on the theory of rock fragmentation and the method of the coal winning machinery design to design the longitudinal-axis tunneling machine EBZ45, including the improvement of the machine reducer, designing the parameters of the pick arrangement of the cutting header and the welding fixtures of the picks, finally, studying the property of the pick cutting the rock.
Have a research of the tunneling machine EBZ45, designed and made improvement of the reducer which had a lot of problems because of the irrational in the structure, the redesigned reducer shows to have good effect of having uniformly distributed load and improves the service life of the bearings.
Have a research of the arrangement of the picks in the tunneling machine EBZ45, put forward an equal-rise-angle spiral lines to distribute the picks, considering the contour of the cutting head, the characters of the coal, the excavating conditions and the optimal line spacing, and the method is applied to improve the arrangement of the picks in the tunneling machine EBZ45.
Developed a new welding fixtures of the picks at the foundation of the installing angles and the arrangement of the picks which can quickly and accurately locate the pick on the cutting head
Build a finite element model for the pick cutting rock was discussed with the finite element software, The influences of resistance on different cutting angel and the relations between cutting thickness and cutting energy consumption in different cutting angel were discussed, the whole result provides a new way in the field of dynamic modeling and simulation for pick cutting rock
引文
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[3]. E.Mustafa Eyyuboglu,Naci Bolukbasi. Effects of circumferential pick spacing on boom type roadheader cutting head performance. Tunnelling and underground space technology,2005,20(5):418-425.
[4]. N.Bilgin,T.Dincer,H.copur etc.Some geological and geotechnical factors affecting the performance of a roadheader in an inclined tunnel. Tunneling and Underground Space Technology,2004,19(6):629-636.
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[2]. O.Acaroglu,H.Ergin. A new method to evaluate roadheader operational stability[J]. Tunnelling and Underground Space Technology,2006,21:172-179.
[3]. E.Mustafa Eyyuboglu,Naci Bolukbasi. Effects of circumferential pick spacing on boom type roadheader cutting head performance. Tunnelling and underground space technology,2005,20(5):418-425.
[4]. N.Bilgin,T.Dincer,H.copur etc.Some geological and geotechnical factors affecting the performance of a roadheader in an inclined tunnel. Tunneling and Underground Space Technology,2004,19(6):629-636.
[5]. J.Torano Alvarez,M.Menendez Alvarez,R.Rodriguez Diez. Experimental results of a low-Wpower roadheader driving a gallery with different types of rock at the face. Tunnelling and Underground space Technology,2003,18(4):395-404.
[6].王金喜.国外掘进机设计概述.山西煤炭管理干部学院学报,2007,57920：1—2.
[7]. M.Monno, C.Ravasio. The effect of cutting head vibrations on the surfaces generated by water jet cutting. International Journal of Machine Tools & Manufacture,2007,22(1):80-89.
[8]. Norman F.Knight. Pentration simulation for uncontained engine debris impact on fuselage-like panels using LS-DYNA. Finite Elements in Analysis and Design,2003,36(2):99-133.
[9]. D.Karagiozova,R.A.W.Mines. Impact of aircraft rubber type fragments on aluminium alloy plates:Ⅱ-Numerical simulation using LS-DYNA.International Journal of Impact Engineering,2007,34(4):647-667.
[10]. Lijun han,Mijia Yang. Re-fracture process and mechanical charateristics of cracked rock samples. International Journal of Rock Mechanics & Mining Sciences,2009,46(4):738-747.
[11].李晓豁,丛日永.不同钻进参数掘进机切削图的模拟研究.2007.2.
[12].李晓豁.掘进机截割的关键技术研究.北京：机械工业出版社,2007.10
[13].陈淑莲,黄日恒.掘进机横截割头运动规律和儿何模型.中国矿业大学学报,1996,25(1)：79-84
[14].高春华,赵东劲.纵轴式掘进机截齿排列及制作方法探讨.煤炭技术.1998 (1)
[15].黄日恒.悬臂式掘进机.徐州：中国矿业大学出版社,1996
[16].温学峰,武丕炯.讨论悬臂式掘进机截割技术.山西煤炭.2000.3(1)
[17].李佐民,刘玉荣,张凤岩.掘进机截割头最佳截线间距的探讨.煤炭技术.2000.2(2)
[18].姬国强,廉自生,卢绰.基于LS-DYNA的镐形截齿截割力模拟.科学之友.2008.4
[19].项阳.悬臂掘进机纵轴式截割头运动学与力学特性的研究.贵州工业大学,1999.5
[20].马平,朱旬,索双富等.横轴式掘进机切割头截齿运动分析.水利采煤与管道运输,1995.12.4：41～43
[21].李军；部分断面横轴悬臂式掘进机截割头参数验算与优化设计.硕士论文,2005.4：26-46
[22].宁仲良.镐形截齿的应力分布规律研究.西安科技学院学报,2003,23
[23].丁飞.采煤机工作机构CAD及薄煤层小直径滚筒装煤性能的研究.硕士学位论文,辽宁工程技术大学.2003.4.1
[24].张鑫,杨梅.掘进机截割头钻进工况的载荷的计算机模拟.山东科技大学学报,2005(9)：21～23
[25].徐小奥.截割头截齿安装定位的设计方法.煤矿机电,2005(4)：11～14
[26]. Wittchen,V.Clay. Road header excavation in consolidated rock fills at Kidd Creek Mines. CIM Bulletin,1990,83(5):41-45
[27]. Kebire Kel;Nuri Akcin; H.Tuncdemir.Cuttability Characteristics of Some High Strength Rocks for
[28].周爱国.纵轴式切割头设计的研究.中国矿业大学硕士论文,1997.6：34-45
[29].吴宏观,张福润,宾宏赞,回转体上等螺旋角螺旋形刀刃的研究.华中理工大学学报,1997.3,25：11-14.
[30].姬广平,杨瑞十,杨锡军.悬臂式煤巷掘进机截齿装设角度的分析.河北工程技术保定专科学校学报,2001.9,3：31～33
[31].高春花,范春梅,高志明.掘进机截割头截齿排列表示方法的探讨.煤矿机械,1998,3：25～27
[32].李晓豁.基于等螺旋升角的不同形状截割头截齿排列参数化.煤矿机械,2009
[33].番玮.测量截割头上截齿空间位置的一种方法.煤炭科学技术,1999,11.
[34]. Barnes.Numerical analysis of rotary cutting heads.Tunnels & Tunnelling,1996,28(3):40-41
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