Research on Spiral Angle Optimization for Longitudinal Road Header's Cutting Head

Abstract

The cutting head is the key component of a road header in tunnel excavation, where the concept of the spiral angle design directly affects the comprehensive performance, which includes cutting resistance, fluctuation coefficient, specific energy consumption, cutting head stress distribution, and so on. Based on the theory of rock-breaking by pick, the mechanical model of pick was established, and the three-dimensional force vector in the WORKBENCH coordinate system was determined. The 3D model of the proposed cutting head was designed using PRO/E and the static simulation was carried out using WORKBENCH, while the stress information of key parts was obtained. Furthermore, a four-dimensional fitting method was used to investigate the influence of the horizontal swing speed, rotational speed, and spiral angle of the cutting head, on the stress of the cutting head assembly. By setting the horizontal swing speed, rotational speed and the spiral angle as design variables and the specific energy consumption, total cutting resistance, fluctuation coefficient, power consumption, and stress on cutting head assembly as the objective function; the multiobjective optimization function of the cutting head was established. By using genetic algorithm, the complex problem has been solved. The solution of this optimization function provides the horizontal swing speed, rotational speed, and spiral angle values, where the optimal performance is achieved, in the aspect of energy consumption, cutting resistance, fluctuation coefficient, cutting power, and cutting motor power. This method provides solid guidance and is a great reference in spiral angle design and optimization. © IMechE 2020.