• Tunnel and Underground Space
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• v.23 no.5
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• pp.428-441
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• 2013

Nowadays, a roadheader as a mechanical excavator is in high demand, especially for mines under various conditions and tunnels where TBMs are inapplicable. However, the records of roadheaders in Korea are seldom reported. Moreover, the number of countries with their intrinsic design and manufacturing technologies of roadheaders is very limited. Therefore, this study aimed to analyse the excavation principles of roadheader as well as its key design parameters for its optimized selection and design. In addition, the database with 143 world-widely collected roadheader design data was built, and a few statistical correlations were derived from it. A schematic procedure for roadheader design based on the database was also proposed.

• Tunnel and Underground Space
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• v.33 no.3
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• pp.141-149
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• 2023

Recently, as the demand for urban underground space increases, urban tunnel planning is actively progressing. In particular, the application of the roadheader excavation method, which has favorable applicability to urban tunnel, is increasing. However, it is known that the roadheader excavation method has a limitation in that excavation efficiency for high strength rock with a Uniaxial Compressive Strength (UCS) of 100 MPa or more is lowered. In this study, The pre-cracked method was presented as a method to improve the excavation efficiency of roadheader for high strength rock and its applicability was evaluated. The net cutting rate was evaluated using the Bilgin prediction formula, which can calculate the net cutting rate by considering the UCS and RQD (Rock Quality Designation). It was found that the net cutting rate increased as the RQD decreased under the rock condition with the same UCS. This is judged to increase the excavation efficiency of the roadheader in the jointed high strength rock. Additionally, the field applicability of the pre-cracked method for high strength rock was verified through field tests. It was confirmed that the crack zone was formed around the charging hole, and it is considered that the pre-cracked method can be applied to the high strength rock.

• Geotechnical Engineering
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• v.36 no.2
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• pp.6-16
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• 2020

• Magazine of korean Tunnelling and Underground Space Association
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• v.23 no.1
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• pp.61-80
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• 2021

• Tunnel and Underground Space
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• v.25 no.6
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• pp.496-504
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• 2015

Roadheader that excavates ground using pick cutters installed on the cutting head is one of the partial-face machines. A conical cutter among pick cutters is excavation tool decreasing the loss of cutter using tungsten carbide insert at the tip of the cutter and it has been widely used in the roadheaders. In this study, durability performance for three kinds of conical cutters was evaluated in copper mines composed of Manto and conglomerate. After field test, the visual inspection as well as the weight loss measurement of pick cutters was carried out to investigate the damage of pick cutters. In addition, CT scan and SEM were performed to check whether or not crack and apertures in pick cutters. As results, the conical cutter with hardfacing was evaluated as having the best durability performance and it was unable to find cracks in all cutters investigated.

• Journal of Korean Tunnelling and Underground Space Association
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• v.25 no.3
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• pp.221-243
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• 2023

The use of roadheaders has been increasing to mitigate the problems of noise and vibration during tunneling operations in urban area. Since lack of experience of roadheader for hard rock, the selection of appropriate machines and the evaluation of cutting rates have been challenging. Currently, empirical models developed overseas are commonly used to evaluate cutting rates, but their effectiveness has not been verified for domestic rocks. In this paper, a comprehensive literature review was conducted to assess the rock cutting force, cutterhead capacity, and cutting rate to select the appropriate machine and evaluate its performance. The cutterhead capacity was reviewed based on the literature results for the site. Furthermore, a new empirical model and simplified method for predicting cutting rates were proposed through data analysis in relation to operation time and rock strength, and compared with those of the conventional model from the manufacturer. The results show good agreement for high strength range upper 80 MPa of uniaxial compressive strength.

• Tunnel and Underground Space
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• v.32 no.6
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• pp.386-396
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• 2022

To analyze the influence of variables of roadheaders, the linear cutting testing data of pick cutter were collected from the former literatures. The input factors were set up as uniaxial compressive strength, cutting depth, cutting spacing, attack angle, skew angle, and output factors were determined as specific energy, average cutting force, maximum cutting force, average vertical force, and maximum vertical force. After composing a table of the design of experiment (DOE). The contribution level of each factor was calculated by analysis of variance (ANOVA). As a result, the factors having greatest influence on cutting force and specific energy were uniaxial compressive strength and cutting spacing.

• Journal of Korean Tunnelling and Underground Space Association
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• v.16 no.6
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• pp.573-584
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• 2014

In this study, the variations of cutter acting forces depending on cutting conditions were examined to obtain basic data for roadheader cutting head design. The linear cutting tests were performed in the condition of different attack angles, penetration depths, cutter spacings by using a slim conical pick for the light cutting condition. Cutter acting forces were measured by 3-directional load cell under different test conditions, and the analysis for cutting performance were carried out after calculating average values of the measured results. It is confirmed that the optimal cutting condition for the mortar specimen is the 50 degree attack angle, the cutter spacing of 12 mm, the cutting depth of 9 mm which are obtained from the analysis results. In addition, 50 degree attack angle is more effective than 45 degree attack angle to design optimal specifications of cutting head.

• Tunnel and Underground Space
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• v.31 no.6
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• pp.440-459
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• 2021

Roadheaders have begun to be adopted in Korean tunneling sites. The performance prediction models proposed by the manufacturer are used by Korean construction companies. The models use UCS (uniaxial compressive strength) value to predict the net cutting rate, but the rock specimens conducted for the uniaxial compression test have 1.0 of the diameter to length ratio. It has been reported that the specimen shape generally influences the rock strength. The previous references studying the shape effect were cited, and the UCS data of Korean rocks are also updated to analyze the shape effect on UCS. The cause of effect was discussed by previous theory. The change amount of UCS values of Korean rocks was estimated by the data, and the modified prediction model for NCR was finally suggested.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.1-7
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• 2016

The pick cutter, which directly contacts and crushes the rock, is the expendable part of a roadheader. The arrangement and angle of attachment of the pick cutter are important factors that determine excavator performance. It is necessary to numerically calculate the contact between the pick cutter and rock. The rock is defined as a set of particles using the discrete element method. The parallel bond model is used to define the bonds between particles. The properties of granite that are measured by the uniaxial compressive test are applied to the numerical rock model. The pick cutter is defined by the polygon elements. The linear cutting simulation is considered to simulate the contact between the pick cutter and rock. The results of the simulation show the rock breaking due to contact with the pick cutter.