Development of a prediction model for maximum cutting temperature of thermodynamically coupled disc cutter

Abstract

The objective of this research is to develop a predictive model for the maximum cutting temperature and optimize parameter control, thereby enhancing cutting performance and tool lifespan. The study employed a combination of experimental techniques and numerical simulations, and Abaqus was used to analyse the thermo-mechanical coupling in disc cutter-rock interactions. The effects of cutting parameters on the performance of the disc cutter were explored, and a regression-based prediction model for maximum cutting temperature was established and validated. The key findings are as follows: As cutting speed increases, the amplitude of cutting force fluctuations rises, while the cutting temperature initially decreases and then increases, accelerating tool wear. The cutting temperature ranges from a minimum of 101.4°C to a maximum of 179.3°C. At lower cutting speeds, heat generation is amplified. As both speed and cutting depth increase, cutting force and impact forces rise, leading to higher cutting temperatures, with recorded peaks of 217.2°C and troughs of 100.5°C. Excessively high speed and depth exacerbate heat generation. Moreover, with an increase in cutting speed, specific cutting energy initially decreases and then rises. While higher cutting speeds improve cutting efficiency and reduce energy consumption, they also lead to more severe impact wear. The prediction model for maximum cutting temperature serves to forecast the peak temperature during rock cutting at specific points in the process, providing a foundation for further studies on rock excavation thermodynamics.