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Based on the spiral cutting pick cutting and crushing method, the cutting and crushing behavior of spiral drum cutting picks on the ore body and the cutting and crushing process were analyzed, and a dynamic model for ore body cutting and crushing based on pick cutting had been constructed. Based on the HMB contact model in EDEM, a simulation model of cutting picks cutting cobalt-rich crust ore bodies was established, a test platform for simulating ore body crushing was prepared, and verification tests on the cutting and crushing force characteristics of single-tooth and full-tooth cutting were carried out. Test and simulation results are basically consistent in overall trends. In the single-tooth spiral drum test, when the cutting speed increases from 0.05 m/s to 0.1 m/s, the cutting resistance increases by 12.2%. In the full-tooth spiral drum test, when the cutting depth increases from 10 mm to 30 mm, the cutting resistance increases by 110%, and the load fluctuation coefficient increases by 43.4%. With the vibration excitation-assisted crushing method, when the cutting depth is 20 mm and 30 mm, the cutting resistance decreases by 16% and 10% respectively. When the cutting depth is 30 mm, the load fluctuation coefficient increases by 16.7%. Test results show that compared with cutting speed, cutting resistance is more sensitive to cutting depth. The greater the cutting depth or the faster the cutting speed, the greater the load fluctuation. The adoption of the vibration excitation-assisted crushing method helps reduce the required cutting force, but the cutting vibration intensifies. The research results can provide technical support for the study on operating parameters of the cutting and crushing technology for deep-sea cobalt-rich crusts and the development of crushing heads.

, authors=Min JIANG1, 2, 3, Xinjiang LU2, Bingzheng CHEN1, 3, Yang AI1, 3, Wei LIU1, 3, authorsList=Min JIANG, Xinjiang LU, Bingzheng CHEN, Yang AI, Wei LIU, authorCompany=null, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1322164695113515442, articleId=1322164686452277628, tenantId=1146029695717560320, journalId=1225396423026438145, language=CN, title=深海富钴结壳螺旋截齿截割破碎受力特性研究, columnId=1226462294582936453, journalTitle=矿业研究与开发, columnName=深部、深海矿产资源勘探与开发, runingTitle=null, highlight=null, articleAbstract=

基于螺旋截齿截割破碎方法,分析了矿体的螺旋滚筒截齿截割破碎行为和截割破碎过程,构建了基于截齿截割的矿体截割破碎动力学模型。基于EDEM的HMB接触模型,建立了截齿截割富钴结壳矿体的仿真模型,制备了模拟矿体破碎试验平台,进行了单齿和全齿的截割破碎受力特性验证试验。试验与仿真结果整体趋势基本一致,在单齿滚筒试验中,当截割速度从0.05 m/s增加至0.1 m/s时,截割阻力增长了12.2%;在全齿螺旋滚筒试验中,当截割深度从10 mm增加至30 mm时,截割阻力增长了110%,载荷波动系数增长了43.4%;采用激振辅助破碎方法,当截割深度为20 mm与30 mm时,截割阻力分别下降了16%和10%,在截割深度为30 mm时,载荷波动系数增长了16.7%。试验结果表明:相对于截割速度,截割阻力对截割深度更敏感,截割深度越大或截割速度越快,载荷波动越大;采用激振辅助破碎方法有助于降低所需截割力,但截割振动加剧。研究成果可为深海富钴结壳截割破碎技术作业参数研究和破碎头的研制提供技术支撑。

, authors=江敏1, 2, 3, 陆新江2, 陈秉正1, 3, 艾杨1, 3, 刘伟1, 3, authorsList=江敏, 陆新江, 陈秉正, 艾杨, 刘伟, authorCompany=null, correspAuthors=null, authorNote=

江敏(1987—),男,湖南株洲人,博士,高级工程师,主要从事深海采矿技术与装备研究。E-mail:

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Particle parameters and bonding parameters of the simulation model of cobalt-rich crust ore body

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颗粒参数黏结参数
颗粒半径/mm接触半径/mm静摩擦因数动摩擦因数单位法向刚度/(N/m)单位切向刚度/(N/m)法向强度/Pa切向强度/Pa
11.10.70.11×10105×1093×1072×106
), ArticleFig(id=1322164701425943041, tenantId=1146029695717560320, journalId=1225396423026438145, articleId=1322164686452277628, language=CN, label=表1, caption=

富钴结壳矿体仿真模型的颗粒参数与黏结参数

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颗粒参数黏结参数
颗粒半径/mm接触半径/mm静摩擦因数动摩擦因数单位法向刚度/(N/m)单位切向刚度/(N/m)法向强度/Pa切向强度/Pa
11.10.70.11×10105×1093×1072×106
), ArticleFig(id=1322164701509829122, tenantId=1146029695717560320, journalId=1225396423026438145, articleId=1322164686452277628, language=EN, label=Table 2, caption=

Load fluctuation coefficients under different working conditions

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截割速度0.8 m/s截割速度0.8 m/s截割速度0.8 m/s截割速度0.6 m/s截割速度1 m/s
截割深度10 mm截割深度20 mm截割深度30 mm截割深度20 mm截割深度20 mm
0.194 80.245 50.281 70.240 50.258 6
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不同工况下的载荷波动系数

, figureFileSmall=null, figureFileBig=null, tableContent=
截割速度0.8 m/s截割速度0.8 m/s截割速度0.8 m/s截割速度0.6 m/s截割速度1 m/s
截割深度10 mm截割深度20 mm截割深度30 mm截割深度20 mm截割深度20 mm
0.194 80.245 50.281 70.240 50.258 6
), ArticleFig(id=1322164701706961412, tenantId=1146029695717560320, journalId=1225396423026438145, articleId=1322164686452277628, language=EN, label=Table 3, caption=

Mechanical testing conditions of ore body cutting and crushing

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工况截割深度/m截割速度/(m/s)滚筒转速/(r/min)有无激振齿数
工况 10.01,0.02,0.030.07545无单齿、全齿
工况 20.020.05,0.075,0.145无单齿
工况 30.02,0.030.07545有全齿
), ArticleFig(id=1322164701795041797, tenantId=1146029695717560320, journalId=1225396423026438145, articleId=1322164686452277628, language=CN, label=表3, caption=

矿体截割破碎力学测试试验工况

, figureFileSmall=null, figureFileBig=null, tableContent=
工况截割深度/m截割速度/(m/s)滚筒转速/(r/min)有无激振齿数
工况 10.01,0.02,0.030.07545无单齿、全齿
工况 20.020.05,0.075,0.145无单齿
工况 30.02,0.030.07545有全齿
), ArticleFig(id=1322164701895705094, tenantId=1146029695717560320, journalId=1225396423026438145, articleId=1322164686452277628, language=EN, label=Table 4, caption=

Average drive motor hydraulic pressure and load fluctuation coefficient with and without vibration excitation at different cutting depths

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序号截割深度/m有无激振平均驱动马达液压压力/MPa载荷波动系数
10.02无10.580.259 1
20.02有9.210.275 3
30.03无14.290.296 7
40.03有13.070.346 2
), ArticleFig(id=1322164701992174087, tenantId=1146029695717560320, journalId=1225396423026438145, articleId=1322164686452277628, language=CN, label=表4, caption=

不同截割深度下有无激振的平均驱动马达液压压力及载荷波动系数

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序号截割深度/m有无激振平均驱动马达液压压力/MPa载荷波动系数
10.02无10.580.259 1
20.02有9.210.275 3
30.03无14.290.296 7
40.03有13.070.346 2
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深海富钴结壳螺旋截齿截割破碎受力特性研究
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江敏 1, 2, 3 , 陆新江 2 , 陈秉正 1, 3 , 艾杨 1, 3 , 刘伟 1, 3
矿业研究与开发 | 深部、深海矿产资源勘探与开发 2025,45(11): 1-9
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矿业研究与开发 |深部、深海矿产资源勘探与开发 2025 , 45 (11) : 1 -9
深海富钴结壳螺旋截齿截割破碎受力特性研究
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江敏(1987—),男,湖南株洲人,博士,高级工程师,主要从事深海采矿技术与装备研究。E-mail:

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江敏(1987—),男,湖南株洲人,博士,高级工程师,主要从事深海采矿技术与装备研究。E-mail:

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江敏1, 2, 3 , 陆新江2, 陈秉正1, 3, 艾杨1, 3, 刘伟1, 3
作者信息
  • 1.长沙矿山研究院有限责任公司,湖南 长沙 410012
  • 2.中南大学,湖南 长沙 410083
  • 3.国家金属采矿工程技术研究中心,湖南 长沙 410012
作者简介:

江敏(1987—),男,湖南株洲人,博士,高级工程师,主要从事深海采矿技术与装备研究。E-mail:

Study on Force Characteristics of Cutting and Crushing of Spiral Cutting Picks for Deep-Sea Cobalt-Rich Crusts
Min JIANG1, 2, 3 , Xinjiang LU2, Bingzheng CHEN1, 3, Yang AI1, 3, Wei LIU1, 3
Affiliations
  • 1.Changsha Institute of Mining Research Co., Ltd., Changsha, Hunan 410012, China
  • 2.Central South University, Changsha, Hunan 410083, China
  • 3.National Engineering Research Center for Metal Mining, Changsha, Hunan 410012, China
出版时间: 2025-11-25
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基于螺旋截齿截割破碎方法,分析了矿体的螺旋滚筒截齿截割破碎行为和截割破碎过程,构建了基于截齿截割的矿体截割破碎动力学模型。基于EDEM的HMB接触模型,建立了截齿截割富钴结壳矿体的仿真模型,制备了模拟矿体破碎试验平台,进行了单齿和全齿的截割破碎受力特性验证试验。试验与仿真结果整体趋势基本一致,在单齿滚筒试验中,当截割速度从0.05 m/s增加至0.1 m/s时,截割阻力增长了12.2%;在全齿螺旋滚筒试验中,当截割深度从10 mm增加至30 mm时,截割阻力增长了110%,载荷波动系数增长了43.4%;采用激振辅助破碎方法,当截割深度为20 mm与30 mm时,截割阻力分别下降了16%和10%,在截割深度为30 mm时,载荷波动系数增长了16.7%。试验结果表明:相对于截割速度,截割阻力对截割深度更敏感,截割深度越大或截割速度越快,载荷波动越大;采用激振辅助破碎方法有助于降低所需截割力,但截割振动加剧。研究成果可为深海富钴结壳截割破碎技术作业参数研究和破碎头的研制提供技术支撑。

深海采矿  /  富钴结壳  /  力学特性  /  螺旋截齿滚筒  /  截割破碎试验

Based on the spiral cutting pick cutting and crushing method, the cutting and crushing behavior of spiral drum cutting picks on the ore body and the cutting and crushing process were analyzed, and a dynamic model for ore body cutting and crushing based on pick cutting had been constructed. Based on the HMB contact model in EDEM, a simulation model of cutting picks cutting cobalt-rich crust ore bodies was established, a test platform for simulating ore body crushing was prepared, and verification tests on the cutting and crushing force characteristics of single-tooth and full-tooth cutting were carried out. Test and simulation results are basically consistent in overall trends. In the single-tooth spiral drum test, when the cutting speed increases from 0.05 m/s to 0.1 m/s, the cutting resistance increases by 12.2%. In the full-tooth spiral drum test, when the cutting depth increases from 10 mm to 30 mm, the cutting resistance increases by 110%, and the load fluctuation coefficient increases by 43.4%. With the vibration excitation-assisted crushing method, when the cutting depth is 20 mm and 30 mm, the cutting resistance decreases by 16% and 10% respectively. When the cutting depth is 30 mm, the load fluctuation coefficient increases by 16.7%. Test results show that compared with cutting speed, cutting resistance is more sensitive to cutting depth. The greater the cutting depth or the faster the cutting speed, the greater the load fluctuation. The adoption of the vibration excitation-assisted crushing method helps reduce the required cutting force, but the cutting vibration intensifies. The research results can provide technical support for the study on operating parameters of the cutting and crushing technology for deep-sea cobalt-rich crusts and the development of crushing heads.

Deep-sea mining  /  Cobalt-rich crust  /  Mechanical property  /  Spiral cutting pick drum  /  Cutting and crushing test
江敏, 陆新江, 陈秉正, 艾杨, 刘伟. 深海富钴结壳螺旋截齿截割破碎受力特性研究. 矿业研究与开发, 2025 , 45 (11) : 1 -9 .
Min JIANG, Xinjiang LU, Bingzheng CHEN, Yang AI, Wei LIU. Study on Force Characteristics of Cutting and Crushing of Spiral Cutting Picks for Deep-Sea Cobalt-Rich Crusts[J]. Mining Research and Development, 2025 , 45 (11) : 1 -9 .
钴是新能源领域中的关键金属元素。随着新能源及电子元器件的迅速发展,我国对钴的需求量不断增加[1]。海洋中蕴含着大量的钴资源,随着深海工程技术的发展,深海矿产资源再次成为热点[2-3]。深海采矿技术是资源获取的关键手段,目前国际上已形成了如图1所示的深海采矿系统。在深海采矿流程中,最前端的环节是矿物集矿,而矿体截割破碎是集矿的核心关键技术之一,其效果直接决定整个深海采矿系统的开采效率,是全球深海开采技术研发的重点方向。
针对深海富钴结壳矿体资源的截割破碎,国内外在其相关领域已有少量研究。矿体特性与截割性能是截割破碎的关键。LARSON等[4]早期对钴结壳矿体的力学特性开展了试验研究,发现该矿体物理特性适中,与陆地上中等强度的煤矿特性较接近。AOSHIKA等[5]基于前期学者研究成果与真实矿体的试验数据,制备了模拟富钴结壳矿体,开展了富钴结壳模拟矿体的截割试验。HASHIBA等[6]测量了西北太平洋海底富钴结壳的物理特性,并通过对富钴结壳矿体的线性截割试验,验证了切割参数之间的关系。吴鸿云等[7]分析了富钴结壳底质的物理特性,并开展了矿体的力学特性测试,通过试验数据拟合并修正了经验公式。HALKYARD[8]通过试验研究,总结了大量成果,验证了螺旋截齿滚筒截割是当前该资源矿体的最佳破碎方法之一。
随着螺旋滚筒破碎技术在富钴结壳资源应用的推广,国内外开始逐步深入对该技术的研究。截齿滚筒设计是截割破碎的关键因素,QIAO等[9]进行了类似镐形截齿的截割试验,分析了富钴结壳的截割模式和效率,研究了矿体破碎裂纹扩展规律。刘勇等[10]对钻结壳螺旋滚筒式截割进行了理论分析,构建了螺旋滚筒载荷波动与截割平均能耗的数学模型,为截割破碎装置的设计提供了参考。夏毅敏等[11-12]利用分形分布模型描述了破碎规律,开发了退火混合遗传算法,有效优化了采集头的工作参数。此外,相对其他破碎方式截割破碎方式耗能较低,但整体上仍是一种能耗较大的方式,为此,部分学者开始关注截割破碎的高效节能研究工作。朱建新等[13]、邹湘伏等[14]、袁碧华[15]针对振动截割钴结壳破碎减阻机理进行了深入分析,探讨了振动施加对截割阻力的作用效果,并通过正交对比试验对其振动截割破碎性能进行了研究,证实了激振技术能有效降低截割能耗。
本文基于前人研究成果,将建立更为全面的截割破碎动力学模型,通过理论分析、数值仿真和试验验证,从深度、截割速度等关键作业参数方面深入分析截割力的发展规律和影响因素,分析截齿载荷波动情况,以期为截割破碎技术在海底采矿应用提供技术支撑。
深海富钴结壳矿产是一种薄层状、附着于基岩表面的固体矿产资源,其矿床地形凹凸起伏、微地形复杂、开采难度极大。基于螺旋截齿截割具有较好的适应性和应用可靠性等特点,将其应用于富钴结壳矿体的开采破碎作业。富钴结壳的截齿截割破碎运动过程如图2所示。由图2可以看出,该机构的运动可分为水平前进运动和滚筒旋转运动,若作业在特殊情况下需要调整高度,还需要考虑竖直方向运动。对于机构总体而言,其移动主要是平移和上下移动;而对于截齿而言,其运动轨迹为平移、上下移动及旋转运动的叠加,因此截齿的运动较为复杂。截齿的运动影响着矿体和截齿受力,因此需要分析截割破碎机构的运动规律。
针对单个截齿的运动,设截齿滚筒中心初始位置为(x0,y0,z0),截齿截割半径为R,第n个截齿初始角度为θ0(水平X轴方向为零角度),则第n个截齿的初始位置为(x0+Rcosθ0,y0,z0+Rsinθ0)。螺旋滚筒第n个截齿的运动轨迹及速度如图3所示。根据笛卡儿坐标系,作业时滚筒中心以X轴方向速度vx向前运动,以转速ω做顺时针旋转运动,考虑地形的凹凸起伏,不同水平位置的地形高度为h(x)。
第n个截齿齿尖位置为:
式中,yn为第n个截齿到滚筒中心的相对位置,m。
本文中,采集作业时集矿装备采用匀速向前运动,且螺旋截齿滚筒匀速旋转,此时,对式(1)求导,即得到截齿的X、Y、Z三向速度:
式中,vnx、vny、vnz分别为第n个截齿在X、Y、Z方向上的速度,m/s。
富钴结壳截割破碎过程中,破碎机构需要克服矿体截割阻力、集矿装备进给阻力和水中流体阻力[16],而受力的主要承载主体集中在截齿上。根据受力平衡方程,滚筒的总受力可表示为:
式中:F为截割破碎滚筒总受力,N;Ff为截割矿体时矿体对所有截齿产生的总阻抗力,N;Fwd为置于水环境中的螺旋滚筒旋转运动产生的流体阻力,N;Fvd为置于水环境中的螺旋滚筒水平运动产生的流体阻力,N;G为截割破碎机构自身重力,N;FB为截割破碎机构受到流体的浮力作用,N;其中F、Ff、Fwd、Fvd、G和FB均为矢量。
由于螺旋滚筒上有多个截齿,有m个截齿同时参与截割破碎工作,每个截齿截割破碎受力状态各异(见图4),第n个截齿的受力包括截割力Fnτ、进给力Fnr和侧向力Fna,则Ff可表示为:
根据煤炭截割理论及相关试验结果,考虑复杂工况条件,截齿K截割力的3个数值大小分力可表示为[17-19]:
式中:A为矿体平均截割阻抗,取3 000 N/mm[12];br为截齿齿尖接触工作宽度,cm;B为矿体的脆性程度系数,取2.2;hit为第i个截齿t时刻的瞬时截割厚度,cm;tp为平均截线宽度,cm;Km为工作面暴露系数;Kα为截齿截割角影响系数,取0.85;Kτ为截齿齿尖前面形状系数,卵形前刃面截齿取0.9;Kc为截齿排列影响系数,棋盘式排列系数取1.25;Kν为矿压影响系数,富钴结壳在海底由于受到水压的作用,Kν取1.7;β为刀具相对走刀方向的安装角,一般取10°~33.5°;f为截割摩擦因数,一般取0.38~0.42,水中作业可取较小值;Sd为截割磨损面积,cm2;K为接触应力与瞬时抗压强度的比值,一般取0.8~1.5,富钴结壳脆性矿体可取较小值;δ为单轴抗压强度,对富钴结壳矿体而言,一般取2~20 MPa;c1、c2、c3为经验系数。
基于上述理论经验公式,通过代入以上参数可获得单个截齿受力。
由于各截齿空间位置的差异,其所受的切向、法向及侧向力的方向均有所不同,这无疑增加了相对截齿滚筒的受力计算复杂程度。因此,为便于计算,需将各截齿所承受的截割力进行分解,具体分解为水平(X轴方向力Fnx)、垂直(Z轴方向力Fnz)及横向(Y轴方向力Fny)3个方向的力,如图4所示。
分解切向力、法向力和侧向力得到如下公式:
式中,θnt为t时刻的第n个截齿的角度。
假设有m个截齿与矿体同时作用,则滚筒水平(X轴方向力Fx(t))、垂直(Z轴方向力Fy(t))及横向(Y轴方向力Fz(t))3个方向的受力可表示为:
截齿在破碎富钴结壳矿体时所进行的截割过程极为复杂,涉及截齿与矿体之间力和运动的交互作用。矿体的破碎模式及整个破碎过程是研究的核心,而离散元法在这方面展现出显著的优势[20]。本文利用EDEM软件,结合HMB接触模型对截齿截割矿体的过程进行仿真计算。
图5为截割破碎矿体的仿真模型,富钴结壳矿体由无数颗粒黏结而成,其颗粒参数和黏结参数见表1,截齿截割角为45°,截割速度为1.2 m/s(模拟截齿滚筒转动速度45 r/min),截割厚度为20 mm。仿真模型有效模拟了富钴结壳真实矿体整个破碎过程,如图6所示。
在矿体的截割破碎过程中,由于作业工况的复杂性,截齿受力会存在波动变化,从而影响截割力的稳定性。本文引入载荷波动系数δ′,用于表示截割破碎过程中截齿受力的周期性变化程度,则有:
根据定义,截齿受力周期内的平均值和截齿受力周期内的标准差σ的表达式为:
式中,Fi为第i个记录的截割力值。
图7是截割速度为0.8 m/s时3种不同截割深度的截割阻力和进给阻力变化情况,可以看出,截割深度为30 mm时,截割阻力大幅增加,且载荷波动较大。图8是截割深度20 mm条件下不同截割速度的截割阻力和进给阻力,截割速度从0.6 m/s增至1 m/s,平均截割阻力仅增加285 N,增幅仅为14.26%,且3种工况下载荷波动接近,这说明截割速度对截割阻力的影响明显小于截割深度对截割阻力的影响。不同工况下的载荷波动系数见表2。
结合表2、图7和图8可知,随着截割深度的增加,截齿受力也大幅增大,且截割阻力的载荷波动情况也更明显,这主要是因为随着截割深度的增加,截齿与矿体接触范围变大,作业工况更加复杂,受到的截割阻力更容易波动;而同一截割深度下不同截割速度载荷波动变化程度不大,这表明截割深度对载荷波动更为敏感。
截割参数对截齿受力的影响如图9所示。由图9可知,在不同截割速度与截割深度条件下,截齿受力有明显差异。在不同截割速度条件下,截割阻力与进给阻力增幅较为相似,增幅分别为14.3%与15.4%。但在不同截割深度条件下,截割阻力和进给阻力增长趋势很明显,特别是截割阻力成倍增长,截割深度从10 mm增加至30 mm时,截割阻力增长了133%,而进给阻力增长54.6%。因此,截割深度对截齿受力更为敏感。
根据矿体的截割破碎作业分析,截割破碎机构主要受到矿体对截齿滚筒的水平移动阻力和旋转截割阻力、流体对滚筒的旋转黏性阻力、浮力和重力等。考虑各个力方向不一致,要将上述力分解成平移运动X方向和竖直升降Z方向的力,以及滚筒旋转扭矩。矿体截割破碎受力试验方案如图10所示。试验时,玻璃水箱内部充满水,截割破碎机构的滚筒截齿为可更换的单齿滚筒和全齿螺旋滚筒,利用平移位移油缸测量滚筒截割速度和前进截割阻力,利用升降位移油缸测量滚筒截割深度和下压阻力,利用滚筒马达进出口压差获取输出扭矩,并利用转速传感器测量滚筒旋转速度。
实验室试验主要是测试与验证不同截割深度、不同截割后厚度(其由转速与截割速度决定)、有无激振条件下的滚筒受力情况。矿体截割破碎力学测试试验工况见表3。
为了测试试验过程中截齿和滚筒的截割阻力,试验过程中分别安装单齿滚筒和全齿螺旋滚筒,通过截割破碎机构的驱动马达液压压力变化反映截割阻力的情况,液压马达进出口压差每增加1 MPa,其输出扭矩增加180 N•m,滚筒齿尖扫略直径为0.5 m。单齿滚筒试验中,截割速度0.075 m/s时不同截割深度下的截割阻力如图11所示,将单齿安置于滚筒中间位置,在滚筒转速为45 r/min、行驶地车截割速度为0.075 m/s的条件下,分别测试截割深度为10 mm、20 mm和30 mm时的驱动马达液压压力情况,所有压力数据均为单齿接触平均值。从图11中可以看出,在截割深度30 mm时,单齿最大驱动马达液压压力可达到7~8 MPa(包含2~3 MPa的马达液压背压),即在净压差5~6 MPa时最大平均截割力可达到4 320 N,而在截割深度10 mm时最大平均截割力仅约为1 580 N,在截割深度20 mm时最大平均截割力仅约为2 370 N。因此,随着截割深度的增加,驱动马达液压压力显著增加,增长趋势迅猛,矿体的截割破碎受力行为对截割深度较为敏感。
截割深度20 mm时不同截割速度下的截割阻力如图12所示,测试了单齿滚筒在截割深度20 mm和转速45 r/min时不同截割速度下的驱动马达液压压力。由图12可知,截割速度从0.05 m/s至0.1 m/s,最大驱动马达液压压力从4.9 MPa增加到5.5 MPa,截割阻力增加了12.2%,最大截割阻力约为2 520 N,整体增加幅度较小,随着阻力速度的增加,截割阻力的增幅不明显。图中试验结果与本文中的仿真结果较为相似。
图13是全齿螺旋滚筒在截割速度0.075 m/s和转速45 r/min时,不同截割深度下的截割阻力。截割深度为10 mm、20 mm和30 mm时的平均截割驱动马达液压压力分别为7.85 MPa、10.58 MPa和14.29 MPa,即截割深度30 mm的截割阻力为截割深度10 mm的2.1倍(去除背压2 MPa);上述3种工况下的载荷波动系数分别为0.206 9,0.259 1和0.296 7,截割深度从10 mm增至30 mm时,载荷波动系统增长了43.4%。由此可知,随着截割深度的增加,截割阻力随之增大,同时截割阻力的波动情况加剧;此外,实验室试验截齿载荷波动稍高于仿真计算,主要是因为实际截割破碎工况比仿真工况更为复杂,在仿真中未考虑部分干扰因素。根据试验结果可知,在工业生产中截割深度的选择应在满足生产能力的前提下尽量降低大深度截割破碎,同时降低截割深度有利于对设备的截割破碎作业驱动力的波动控制。
为了降低矿体截割破碎所需的截割力,本文设计了垂直激振驱动辅助破碎。图14为在转速45 r/min和推进速度0.075 m/s的条件下,全齿螺旋滚筒截割破碎截割深度分别为20 mm和30 mm时有无激振情况下的截割阻力对比。从图14中可以看出,在施加偏心激振情况下,在截割深度20 mm时,平均截割驱动马达液压压力下降了16%(去除背压);在截割深度30 mm时,平均驱动马达液压压力下降了10%(去除背压)。偏心激振对降低截割阻力有较好效果,但由于截割阻力与激振力方向不一致,截割阻力的波动明显加大。不同截割深度下有无激振的平均驱动马达液压压力及载荷波动系数见表4。从表4可以得出,施加偏心激振的驱动马达液压压力的载荷波动明显高于常规截割破碎,最大增幅为16.7%。因此,施加激振驱动辅助破碎虽有利于降低截割阻力,但截齿的受力稳定性变差,不利于截割阻力稳定和刀具寿命,在实际生产应用中应综合考虑各项因素。
针对富钴结壳矿体的螺旋截齿截割破碎作业,本文开展了螺旋滚筒及截齿的动力学分析,开展了数值仿真与实验室试验验证,获得了截割破碎受力特性和不同参数下的影响规律。得出的主要结论如下。
(1)建立了富钴结壳矿体的截割破碎动力学模型,基于EDEM平台的HMB接触模型,建立截齿截割富钴结壳矿体的仿真模型,分析了不同截割深度和速度下截齿截割受力特性,引入了载荷波动系数,得到了截割深度从10 mm增至30 mm,截齿所受截割阻力增加了133%,而截割速度从0.6 m/s增至1.0 m/s,截割阻力仅增加14.3%,因此,截割深度对截割阻力的影响比截割速度更明显。
(2)搭建了富钴结壳模拟矿体截割破碎试验平台,开展了截割破碎受力特性试验,验证了单截齿受力影响规律和发展趋势与其仿真结果基本一致。单齿滚筒试验中,截割速度从0.05 m/s增加至0.1 m/s时,截割阻力增长了12.2%;全齿螺旋滚筒试验中,截割深度从10 mm增加至30 mm时,截割阻力增长了110%,在截割深度为30 mm时,波动系数增长了43.4%;实验室试验载荷波动数据稍大于仿真数据,主要是因为真实工况更为复杂,载荷波动更为激烈,影响了截割力的稳定性。
(3)采用激振辅助破碎方法,通过试验验证了该方法可有效降低所需截割力,在截割深度为20 mm和30 mm时,截割阻力降幅分别为16%和10%,但通过该方法,颗粒载荷波动明显加大,最大增幅16.7%,这主要归结于激振力的干扰作用。
(4)受试验条件限制,未考虑深海底大水深环境的围压和水环境因素,实际截割作业受力应有所增加。未来的研究将建立考虑围压和水环境的仿真模型,在围压密闭水环境平台中开展模拟截割破碎试验,并视情况开展海试验证,以探究围压和水环境对截割破碎作业的影响。
  • 国家重点研发计划项目(2021YFC2801702)
  • 湖南省自然科学基金项目(2021JC0010)
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2025年第45卷第11期
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  • 接收时间:2025-02-05
  • 首发时间:2026-10-28
  • 出版时间:2025-11-25
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  • 收稿日期:2025-02-05
基金
国家重点研发计划项目(2021YFC2801702)
湖南省自然科学基金项目(2021JC0010)
作者信息
    1.长沙矿山研究院有限责任公司,湖南 长沙 410012
    2.中南大学,湖南 长沙 410083
    3.国家金属采矿工程技术研究中心,湖南 长沙 410012
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2种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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