Estimation of Rock Cuttability from Shore Hardness and Compressive Strength Properties

Summary Shore hardness has been used to estimate some mechanical and physical properties of rocks for many years. This study differs from previous studies in a way that it is directly oriented to rock cuttability. Two Shore hardness values (SH ₁ andSH ₂) and a coefficient of deformation value (K) have been measured for 30 different rock samples. In the first stage of the study, optimum specific energy values for 16 different rock samples obtained from full-scale cutting tests were correlated with the Shore hardness values of the same rock samples changingSH ₁ values from 9 to 66 andSH ₂ values from 25 to 83, with deformation coefficient values changing from 26 to 195. In the second stage, the performance of a roadheader used in the Kü?üksu (Istanbul) tunnel was recorded in detail and the instantaneous cutting rate of the machine was determined. Then, the relationship between Shore hardness values, deformation coefficient and the instantaneous cutting rate of the machine was determined for different formations encountered. It is concluded that there is a relationship between Shore hardness values, optimum specific energy and compressive strength, which may be used to estimate the rock cuttability and the instantaneous cutting rates of roadheaders within certain limits of reliability.     

岩石切削机理模型分析及实验研究

切削机理模型是研究岩石钻进切削过程中的切削力以及切削热的基础。在分析岩石切削机理模型的基础上,基于摩尔理论和裂纹扩展理论,分析中硬岩石切削状态,认为在中硬岩石切削过程中岩石存在着脆性切削和延展性切削2种方式,在此基础上得到新的中硬岩石切削机理模型。以砂岩、大理岩和花岗岩为钻进对象,开展微钻实验研究。结果表明：切削过程为岩石在刀具的扭矩和推进力作用下发生破坏,导致小岩屑、大切屑不断循环产生的过程,小大切屑形成主要源于岩石挤压变形和裂纹生成扩展。实验结果与岩石切削机理表现出较好的一致性。     

基于断裂力学的岩石切削数值分析探讨

为研究岩石切削过程中刀具的力学特性以及刀具平均峰值作用力的预测,基于断裂力学和有限元理论建立了岩石切削的数值模型。模拟分析岩石对刀具的反作用过程,得到不同力学特性岩石和刀具作用条件下刀具所受的反作用力,结果表明,冲击速度在一定范围内对刀具平均峰值作用力影响较小;岩石体积呈阶跃性递减,刀具作用力大小与崩落岩石碎片体积变化一致。对模拟、实验以及已有理论计算得到的刀具平均峰值作用力进行线性回归分析,研究结果表明,数值方法计算结果与实验结果、Goktan[1]理论计算结果的线性相关系数分别为0.812、0.930,相关性较好,表明所建数值模型用于模拟岩石切削是正确和可靠的。     

A spatial estimation model for continuous rock mass characterization from the specific energy of a TBM

Summary  Basic principles of the theory of rock cutting with rolling disc cutters are used to appropriately reduce tunnel boring machine (TBM) logged data and compute the specific energy (SE) of rock cutting as a function of geometry of the cutterhead and operational parameters. A computational code written in Fortran 77 is used to perform Kriging predictions in a regular or irregular grid in 1D, 2D or 3D space based on sampled data referring to rock mass classification indices or TBM related parameters. This code is used here for three purposes, namely: (1) to filter raw data in order to establish a good correlation between SE and rock mass rating (RMR) (or tunnelling quality index Q) along the chainage of the tunnel, (2) to make prediction of RMR, Q or SE along the chainage of the tunnel from boreholes at the exploration phase and design stage of the tunnel, and (3) to make predictions of SE and RMR or Q ahead of the tunnel’s face during excavation of the tunnel based on SE estimations during excavation. The above tools are the basic constituents of an algorithm to continuously update the geotechnical model of the rock mass based on logged TBM data. Several cases were considered to illustrate the proposed methodology, namely: (a) data from a system of twin tunnels in Hong Kong, (b) data from three tunnels excavated in Northern Italy, and (c) data from the section Singuerlin-Esglesias of the Metro L9 tunnel in Barcelona. Correspondence: G. Exadaktylos, Department of Mineral Resources Engineering, Technical University of Crete, Chania, Greece     

The Effects of Operational Parameters on a Mono-wire Cutting System: Efficiency in Marble Processing

Mono-wire block cutting machines that cut with a diamond wire can be used for squaring natural stone blocks and the slab-cutting process. The efficient use of these machines reduces operating costs by ensuring less diamond wire wear and longer wire life at high speeds. The high investment costs of these machines will lead to their efficient use and reduce production costs by increasing plant efficiency. Therefore, there is a need to investigate the cutting performance parameters of mono-wire cutting machines in terms of rock properties and operating parameters. This study aims to investigate the effects of the wire rotational speed (peripheral speed) and wire descending speed (cutting speed), which are the operating parameters of a mono-wire cutting machine, on unit wear and unit energy, which are the performance parameters in mono-wire cutting. By using the obtained results, cuttability charts for each natural stone were created on the basis of unit wear and unit energy values, cutting optimizations were performed, and the relationships between some physical and mechanical properties of rocks and the optimum cutting parameters obtained as a result of the optimization were investigated.     

Discrete element modelling of rock cutting: from ductile to brittle transition

It is well accepted that there is a transition of failure mode from ductile to brittle with increasing depth of cut during rock cutting process. Rock failure modes affect cutting efficiency, and knowledge of the failure transition is essential to the determination of optimum cutting parameters. The critical transition depth can be linked with rock properties. In this study, an attempt was made to model rock cutting process and to check the dependence of the critical failure mode transition depth on the brittleness of rock. For this purpose, dimensional analysis was first performed to establish the correlations between rock macro‐properties and micro‐parameters for discrete element simulations. Following the specimen calibration procedure, two types of synthetic rocks having approximately the same uniaxial compressive strength were generated as the synthetic specimens for simulating the rock cutting process. The first specimen was created using conventional model construction method with identical bond strengths between particles, giving rise to undesirably high indirect tensile strength. The second specimen was created using a proposed clustering algorithm such that the ratio between the tensile and compressive strength matches reasonably well with that of real rocks. The results of rock cutting simulations demonstrate that failure mode transition took place in both models, but for the clustered model the transition emerged at a shallower cutting depth. A further exploration was made to derive the critical depth for this transition based on the simulations performed on the clustered models. The derived relationship indicates that the critical transition depth decreases as strength ratio or brittleness of the rock increases. This provides a very useful tool for predicting the critical depth which can be used to help cutting tool design and cutting parameter optimisations. Copyright © 2015 John Wiley & Sons, Ltd.     

Predicting the Performance of Chain Saw Machines Based on Shore Scleroscope Hardness

Shore hardness has been used to estimate several physical and mechanical properties of rocks over the last few decades. However, the number of researches correlating Shore hardness with rock cutting performance is quite limited. Also, rather limited researches have been carried out on predicting the performance of chain saw machines. This study differs from the previous investigations in the way that Shore hardness values (SH₁, SH₂, and deformation coefficient) are used to determine the field performance of chain saw machines. The measured Shore hardness values are correlated with the physical and mechanical properties of natural stone samples, cutting parameters (normal force, cutting force, and specific energy) obtained from linear cutting tests in unrelieved cutting mode, and areal net cutting rate of chain saw machines. Two empirical models developed previously are improved for the prediction of the areal net cutting rate of chain saw machines. The first model is based on a revised chain saw penetration index, which uses SH₁, machine weight, and useful arm cutting depth as predictors. The second model is based on the power consumed for only cutting the stone, arm thickness, and specific energy as a function of the deformation coefficient. While cutting force has a strong relationship with Shore hardness values, the normal force has a weak or moderate correlation. Uniaxial compressive strength, Cerchar abrasivity index, and density can also be predicted by Shore hardness values.     

Predicting the Building Stone Cutting Rate Based on Rock Properties and Device Pullback Amperage in Quarries Using M5P Model Tree

One of the key parameters that affect the selection of equipment and the cost estimation of dimension stone quarries is the rock cutting rate or production rate. In this study, the M5P tree algorithm is used to determine the relationship between the hard rock sawability and its factors especially the physical and mechanical characteristics of rock. To achieve the research goal, a variety of eleven types of hard dimension stone were selected and nine major physical and mechanical characteristics of rock including uniaxial compressive strength, Young’s modulus, Brazilian tensile strength, equivalent quarts content, grain size, Mohs hardness, point load test, density and P-wave velocity of these samples were evaluated. The cutting rate of diamond wire for all of the Workpiece was measured at different pullback amperage with a fully instrumented cutting platform in laboratory. All operational parameters of cutting process were entirely controlled. Thus, a database containing 99 datasets was provided and it has been used for analyses. The obtained results from the pruned and unpruned tree models showed a significant relationship between cutting rate and its factors. In the end, the results of M5P tree method were compared with statistical analyses (i.e., linear and nonlinear regression). The coefficient of determination be equal with 0.92, 0.86, 0.77 and 0.63 for unpruned tree, pruned tree, linear and nonlinear regression method respectively. This comparison showed that the both method of M5P tree technique have a better performance in predicting the cutting rate rather than the statistical regression methods.     

Quantitative assessment of rock texture and correlation with drillability and strength properties

Summary A dimensionless quantitative measure of rock texture, describing grain: —shape, orientation, degree of grain interlocking and relative proportions of grains and matrix (packing density) has been developed. Data required for the model are obtained by image analysis of thin sections and concerns percentage areas of grains and matrix, length, breadth, perimeter, orientation and area of each grain in the viewing window. The results of rock strength, diamond and percussion drillability tests in eleven sandstones, marbles and igneous rocks are reported, and correlated with the developed texture coefficient. The texture coefficient returns highly statistically significant correlations with rock strength and drillability data. Sandstones have low texture coefficients and high drillability whereas igneous rocks have high texture coefficients and low drillability. With particular reference to percussive drillability it is suggested that extensional crack propagation in the sandstones in an energy efficient process since fracture paths propagate through the weak phyllosilicate matrix. Extensional crack propagation in the igneous rocks is an energy intensive process since a significant proportion of the available drilling energy is consumed in the formation of intra-granular fracture paths. Observational and correlated data are supportive of the suggestion that the texture coefficient is a measure of the resistance of the microstructure of a rock to crack propagation, whether it be inter-or intra-granular. The texture coefficient can be used as a predictive tool for the assessment of drillability and rock strength properties. The technique offers a useful approach in understanding fracture initiation and growth as controlled by the texture of intact rock samples.     

刃具斜切入破岩的试验与研究

介绍了刃具斜切入破岩的试验装置及试验结果，推导出了跃进载荷的计算公式，并对试验结果进行了理论分析，探讨了影响刃具侵入岩石难易的因素和影响破岩比功大小的因素。     

An Empirical Correlation of Index Geomechanical Parameters with the Compressional Wave Velocity

The geomechanical strength of rockmass plays a key role in planning and design of mining and civil construction projects. Determination of geomechanical properties in the field as well as laboratory is time consuming, tedious and a costly affair. In this study, density, slake durability index, uniaxial compressive strength (UCS) and P-wave velocity tests were conducted on four igneous, six sedimentary and three metamorphic rock varieties. These properties are crucial and used extensively in geotechnical engineering to understand the stability of the structures. The main aim of this study is to determine the various mechanical properties of 13 different rock types in the laboratory and establish a possible and acceptable correlation with P-wave velocity which can be determined in the field as well as laboratory with ease and accuracy. Empirical equations were developed to calculate the density, slake durability index and UCS from P-wave velocities. Strong correlations among P-wave velocity with the physical properties of different rock were established. The relations mainly follow a linear trend. Student’s ‘t’ test and ‘F’ test were performed to ensure proper analysis and validation of the proposed correlations. These correlations can save time and reduce cost during design and planning process as they represent a reliable engineering tool.     

尼日尔Termit盆地上白垩统储层岩石学特征及控制因素分析

本文对尼日尔Termit盆地17口井218个井壁取芯样品开展普通薄片、阴极发光、X衍射、扫描电镜及重矿物分析,研究上白垩统储层的岩石学特征,并探讨其控制因素。实验分析结果表明,Termit盆地上白垩统储层的岩石类型主要为石英砂岩,成分成熟度高,以石英为主,含量达86%以上,钾长石、方解石及斜长石等含少量,占比约5%,这种岩石类型对原生孔隙的保存比较有利;填隙物主要为粘土杂基,含量为7%左右,矿物成分以高岭石为主,利于对晶间孔的保留;岩石中发育硅质、方解石和铁质等胶结类型,胶结物的含量占比较小,对储层的破坏作用不大;重矿物类型为磁铁矿、赤铁矿、锆石、磷灰石,推测物源区的母岩类型主要为花岗岩;以细粒结构和少量的不等粒结构为主,分选中等-差,磨圆度一般为次棱角-次圆状,磨圆差。与国内石英砂岩沉积于高能的滨浅海环境不同,研究区石英砂岩成分成熟度高,但分选程度和磨圆度较低,一方面反映了物源区母岩富含石英,同时也反映了这种石英砂岩沉积于近源的河流-三角洲环境。影响研究区上白垩统储层物性的主要因素是岩石类型及成岩作用,由于储层的岩石类型为石英砂岩,压实作用对储层的破坏作用较一般岩石类型偏小。砂岩埋深小于2500m时,主要发育原生孔隙,面孔率大于15%。溶蚀作用对本区储层产生一定的影响,最常见的为长石的溶蚀,溶蚀作用形成粒内溶孔和粒间溶孔,还会扩大原生孔隙形成混合孔,改善了砂岩的储集性能。     

Effect of cutting depth and line spacing on the cuttability behavior of sandstones by conical picks

Various types of conical picks in different shapes are produced and widely employed on mechanical excavators. Depending on the mechanical and abrasivity properties of rocks, appropriate shape of pick is selected. In order to obtain maximum efficiency from the pick during excavation, the interaction between the pick and rock and the cutting mechanism play very important role. In this context, linear cutting tests were conducted by using a conical pick at the cutting depths between 3 and 18 mm and also at the various line spacings on sandstones exhibiting different mechanical properties. The results indicated that cutting depth and line spacing have significant influences on the tool forces acting on the pick, the ratio of normal to cutting force, and the specific energy. Accordingly, strong correlations and empirical models were developed. In conclusion, the empirical models proposed for estimating the forces and specific energy would be used for producing the conical bits and also designing the cutter heads of mechanical excavators on soft and medium-hard strength sandstones.     

Prediction of specific energy of carbonate rock in industrial stones cutting process

Specific energy (SE) measurements of circular saws were conducted on 12 different carbonate rocks. Rock samples were collected from the factories for laboratory tests. Bulk density, apparent porosity, uniaxial compressive strength, Brazilian tensile strength, flexural strength, Schmidt rebound hardness, Shore hardness, point load strength index, Los Angeles abrasion values, and P-wave velocity values were determined in the laboratory. SE and rock properties were evaluated using simple regression analysis and empirical equations were developed. The equations were verified by statistical tests. Regression analysis showed that high correlations exist between SE and uniaxial compressive strength, Shore and Schmidt hardness, bulk density, apparent porosity, and flexural strength. It was found that the SE value of rocks in cutting process was highest for those rocks having the high density, compressive strength, flexural strength, Schmidt and Shore hardness, point load strength index, and P-wave velocity values.     

组合切削具产生的预破碎区对钻进效果的影响

从组合切削具将在岩石中产生预破碎区的论点出发,通过实验定量研究了预破碎区深度与掏槽刃切入深度的关系,得出了预破碎区有利于降低岩石强度及岩石破碎能耗的结论,并用生产试验结果进行了验证。提出了孕镶金刚石钻头钻进Ⅶ～Ⅷ级硬岩时仍存在预破碎区和切削、微切削破岩方式,以及预破碎区并非越大越好的学术观点。     

Numerical Studies on Chip Formation in Drag-Pick Cutting of Rocks

A two dimensional non-linear finite element simulation model has been developed using a mathematical model for progressive rock failure for understanding the mode and sequence of rock failure under a drag pick cutter. Rock cutting simulation has also been done using linear elastic modeling using local stability factor contouring. It has been observed from the simulation results that during negative rake angle cutting the chipping occurs by shear failure of the elements. Whereas, in positive rake angle cutting, some elements were observed to fail in shear and some under tension. The predicted peak cutting force using the developed models was found to be up to 25% higher than the experimental values. The effect of input parameters such as rake angle, flank wear, depth of cut and rock properties on the predicted peak cutting force has been studied, verified from earlier experimental studies and compared with some earlier proposed theories on rock cutting. The elastic stress analysis model based on the stability factor contouring method has also been found to be an effective tool to bracket the expected peak cutting force for a given operational and rock parameters but failed to simulate the effect of pick geometry (rake angle) correctly. The non-linear simulation model using progressive rock element failure is superior to elastic linear stress analysis model by simulating the correct trends for all the rock and machining parameters.     

顺层岩质路堑边坡稳定性的敏感性因素分析

运用弹塑性理论和有限元法,建立了顺层岩质路堑边坡稳定性的模拟分析模型。结合沪蓉国道主干线湖北宜昌至恩施高速公路的顺层岩质路堑高边坡工程,分析了结构面强度、岩层厚度、岩层倾角等各项因素对顺层岩质路堑边坡稳定性的影响,探讨了顺层岩质路堑边坡稳定性的规律。结果表明：软弱结构面的强度参数对顺层岩质路堑边坡稳定性起主要控制作用,岩层倾角对顺层岩质路堑边坡的稳定性也有明显的影响。在该工程的地质条件下,当岩层倾角为38°左右时,顺层路堑边坡的稳定性最差。     

Influence of physico-mechanical properties of Indian dimension stones on cutting rate of diamond wire saw

Cutting performance of diamond wire saw is a key factor influencing mine planning, production scheduling, and equipment selection for dimension stone quarries. It is normally measured in terms of cutting rate. Rock samples collected from various granite and marble quarries in India were tested in laboratory to determine their physico-mechanical properties. Cutting rate of diamond wire saw was measured in the field studies during the actual cutting process in quarries. Using these laboratory determined properties and the cutting rate, a multiple linear regression model has been developed to predict the cutting rate of diamond wire saw. Physico-mechanical properties of rocks determined in laboratory are used as independent variables and cutting rate as predictor variable in the regression model. The study indicates that the cutting rate increases with a decrease in most of the hardness and strength parameters of rock. The final model is tested for its goodness of fit indicating a significant linear relation between cutting rate and physico-mechanical properties, namely tensile strength, slake durability index, and Cerchar hardness index with regression coefficient of 94%. The resulting model can be used suitably for different types of hard to medium hard and soft dimension stones. The generalized model for estimating the cutting rate becomes a handy tool for mining engineers to work out operating efficiency, expenses, planning etc. of the dimension stone block cutting.     

PDC钻头综合受力模型的试验研究

模拟钻头上的切削齿的不同的切削断面形状、重叠切削状态及磨损状态,利用PDC切削齿对多种岩样进行了切削试验,研究了切削面积、接触弧长、切削齿后倾角、岩石抗钻强度、切削齿磨损高度等因素对PDC切削齿受力的影响规律。结果表明,切削面积相同情况下切削齿受力随接触弧长、岩石可钻性极值、切削齿磨损高度分别呈线性,幂函数和指数函数趋势变化;切削齿受力最小的后倾角在5～10°区间内。引入弧长系数、磨损高度系数,建立了PDC切削齿综合受力模型。根据力的平衡原理,推导得出完整的PDC钻头受力计算模型,为PDC钻头优化设计和合理使用提供了理论依据。     

Performance Prediction of Large-Diameter Circular Saws Based on Surface Hardness Tests for Mugla (Turkey) Marbles

Surface hardness tests such as Shore hardness (SH) and Schmidt hammer rebound hardness (SR) may provide a quick and inexpensive measure of rock hardness, which may be widely used for estimating the mechanical properties of rock material such as strength, sawability, drillability and cuttability. In the marble industry, circular sawing with diamond sawblades constitutes a major cost in the processing. Therefore, several models based on the relations between hourly slab production (P _hs), rock surface hardness (SH and SR) and mineral grain size (S _cr) were developed using the data obtained from field and laboratory measurements on five different marbles quarried in the Mugla Province of Turkey. The models which include surface hardness and crystal size may as well be used for the prediction of sawability (hourly slab production) of carbonate rocks using large-diameter circular saws.