Rational cutting height for large cutting height fully mechanized top-coal caving

Large cutting height fully mechanized top-coal caving is a new mining method that improves recovery ratio and single-pass production. It also allows safe and efficient mining. A rational cutting height is one key parameter of this technique. Numerical simulation and a granular-media model experiment were used to analyze the effect of cutting height on the rock pressure of a fully mechanized top-coal caving work face. The recovery ratio was also studied. As the cutting height increases the top-coal thickness is reduced. Changing the ratio of cutting to drawing height intensifies the face pressure and the top-coal shattering. A maximum cutting height exists under a given set of conditions due to issues with surrounding rock-mass control. An increase in cutting height makes the top-coal cave better and the recovery ratio when drawing top-coal is then improved. A method of adjusting the face rock pressure is presented. Changing the cutting to drawing height ratio is the technique used to control face rock pressure. The recovery ratio when cutting coal exceeds that when caving top-coal so the face recovery ratio may be improved by over sizing the cutting height and increasing the top-coal drawing ratio. An optimum ratio of cutting to drawing height exists that maximizes the face recovery ratio. A rational cutting height is determined by comprehensively considering the surrounding rock-mass control and the recovery ratio. At the same time increasing the cutting height can improve single pass mining during fully mechanized top-coal caving.

Effect of Tip-Blade Cutting on the Performance of Large Scale Axial Fan

The effect of tip-blade cutting on the performance of a large scale axial fan was investigated using computational fluid dynamics(CFD)methods.Experiments verified the numerical simulations.The original fan was compared with the one with tip-cutting in terms of dimensionless characteristic and aerodynamic performance in tip region under the conditions of the maximum efficiency point and near-stall point.The results showed that double leakage flow occurred in tip clearance at maximum efficiency point and spillage of leakage flow from leading edge occurred in tip-blade region at near-stall point for the both two fans;and that tip-cutting with 6% of blade height could reduce the intensity of tip-leakage vortex and increase flow capacity in tip blade region,and hold the stall margin almost the same as the original fan.The maximum efficiency of the fan with tip-cutting was improved by1%,and the ability of total pressure rising was obviously greater than the original fan.

Ground pressure law of fully mechanized large cutting height face in extremely-soft thick seam and stability control in tip-to-face area

When stepped coal getting technology was applied to high seam mining working face, with field observations the following aspects of working face were analyzed based on the inherent conditions of extremely soft thick seam mined by Liangbei Mine, such as the brokenness and activity law of rock seam in the working face, the law of load-bearing of its supports, and the instability character of coal or rock in tip-to-face area. The following are the major laws. Pressure intensity of roof in high seam mining with extremely soft thick seam is stronger than one in slicing and sublevel-caving as a whole. But the greater crushing deformation of coal side makes pressure intensity of roof in the middle of working face be equivalent to one in sublevel-caving. In the middle of working face the roof brokenness has less dynamic load effect than roof brokenness in the two ends of working face. The brokenness instability of distinct pace of roof brings several load-bearings to supports. In condition of extremely soft thick seam, the ratio of resistance increment of supports in two ends of working face is obviously greater than that of supports in the middle. Most sloughing in coal side is triangular slop sloughing caused by shear slipping in high seam mining with extremely soft thick seam. Ultrahigh mining is the major reason for roof fall. Instability of coal or rock in tip-to-face area can be controlled effectively with the methods such as improving setting load of supports, mining along roof by reinforcing floor and protecting the immediate roof in time, and so on.

Stability evaluation method of large cross-section tunnel considering modification of thickness-span ratio in mechanized operation

Purpose-This study aims to research the large cross-section tunnel stability evaluation method corrected after considering the thickness-span ratio.Design/methodology/approach-First,taking the Liuyuan Tunnel of Huanggang-Huangmei High-Speed Railway as an example and taking deflection of the third principal stress of the surrounding rock at a vault after tunnel excavation as the criterion,the critical buried depth of the large section tunnel was determined.Then,the strength reduction method was employed to calculate the tunnel safety factor under different rock classes and thickness-span ratios,and mathematical statistics was conducted to identify the relationships of the tunnel safety factor with the thickness-span ratio and the basic quality(BQ)index of the rock for different rock classes.Finally,the influences of thickness-span ratio,groundwater,initial stress of rock and structural attitude factors were considered to obtain the corrected BQ,based on which the stability of a large cross-section tunnel with a depth of more than 100 m during mechanized operation was analyzed.This evaluation method was then applied to Liuyuan Tunnel and Cimushan No.2 Tunnel of Chongqing Urban Expressway for verification.Findings-This study shows that under different rock classes,the tunnel safety factor is a strict power function of the thickness-span ratio,while a linear function of the BQ to some extent.It is more suitable to use the corrected BQ as a quantitative index to evaluate tunnel stability according to the actual conditions of the site.Originality/value-The existing industry standards do not consider the influence of buried depth and span in the evaluation of tunnel stability.The stability evaluation method of large section tunnel considering the correction of overburden span ratio proposed in this paper achieves higher accuracy for the stability evaluation of surrounding rock in a full or large-section mechanized excavation of double line high-speed railway tunnels.

Mechanism and practice of rock control in deep large span cut holes

Deep large span cut holes are difficult to stabilize. The 7801 cut hole in the Lu'an Wuyang Mine was used as this project's background. The main factors affecting large span cut hole stability are analyzed. Pre- stressed bolting theory was used to design a roof control method for a large span roadway. By reducing the span and applying equal strength coordinated supports the rock could be stabilized. The control prin- ciples and methods are given herein along with the analysis. A double micro arch cross section roadway is defined and its use in solving the current problem is described. Beam arch theory was used to build a model of the double micro arch cross section roadway. A support reverse force model for the arch foot intersection was also derived. A support method based upon reducing the width of the large span in the cut hole is presented. These results show that the reduced span of the roadway roof plus the use of cable anchors and single supports gives an effective way to control the large span cut hole. On site monitoring showed that the reduced span support from the double micro arch cross section roadway design had a significant effect. The roadway surface displacement was small and harmful deformation of the cut hole was effectively controlled. This will ensure its long term stability.

CFD-Based Numerical Analysis of a Variable Cross-Section Cylinder

Using ANSYS-CFX, a general purpose fluid dynamics program, the vortex-induced vibration(VIV) of a variable cross-section cylinder is simulated under uniform current with high Reynolds numbers. Large eddy simulation(LES) is conducted for studying the fluid-structure interaction. The vortex shedding in the wake, the motion trajectories of a cylinder, the variation of drag and lift forces on the cylinder are analyzed. The results show that the vortices of variable cross-section cylinder are chaotic and are varying along the cylinder. In places where cross-sections are changing significantly, the vortices are more irregular. The motion trail of the cylinder is almost the same but irregular. The drag and lift coefficients of the cylinder are varying with the changes of diameters.

Large Eddy Simulation of New Vortex Generator Enhancing Heat Exchange of Solar Energy

This paper put forward a new-type vortex generator enhancing heat exchange of solar air-drier and air-heater on the gas side,and investigated the mechanism of heat transfer enhancement and drag reduction by the influence of vortex generators on the coherent structure of turbulent boundary layer.The flow and heat transfer characteristics of rectangle channel with bevel-cut half-elliptical column vortex generators were obtained using large eddy simulation(LES)and the hydromechanics software FLUENT6.3.The instantaneous properties of velocity,temperature and pressure in channel were gained.The coherent structure of turbulent boundary layer flow was showed,and the characteristic of vortex induced by inclined-cut semi-ellipse vortex generator and its influence on turbulent coherent structure were analyzed.And the effect mechanism of turbulent coherent structure on flow field,pressure field and temperature field was discussed.Based on the results,the heat transfer coefficient and drag reduction of the new vortex generator with different pitch angles were compared.Sometimes,the coherent effects of the increased wall heat transfer and the decreased skin friction do not satisfy the Reynolds analogy.The turbulent coherent structure can be controlled through the geometry of the vortex generator,so the heat transfer and drag reduction can also be controlled.Then we can seek suitable form of vortex generator and structure parameters,in order to achieve the enhanced heat transfer and flow of drag reduction in the solar air-heater and solar air-drier.

Free-Interface Dual-Compatibility Modal Synthesis Substructure Method in Large-Scale Structures

Free-interface dual-compatibility modal synthesis method(compatibility of both force and displacement on interfaces)is introduced to large-scale civil engineering structure to enhance computation efficiency. The basic equations of the method are first set up, and then the mode cut-off principle and the dividing principle are proposed. MATLAB is used for simulation in different frame structures. The simulation results demonstrate the applicability of this substructure method to civil engineering structures and the correctness of the proposed mode cut-off principle. Studies are also conducted on how to divide the whole structure for better computation efficiency while maintaining better precision. It is observed that the geometry and material properties should be considered, and the synthesis results would be more precise when the inflection points of the mode shapes are taken into consideration. Furthermore, the simulation performed on a large-scale high-rise connected structure further proves the feasibility and efficiency of this modal synthesis method compared with the traditional global method. It is also concluded from the simulation results that the fewer number of DOFs in each substructure will result in better computation efficiency, but too many substructures will be time-consuming due to the tedious synthesis procedures. Moreover, the substructures with free interface will introduce errors and reduce the precision dramatically, which should be avoided.

Analytical study on pretensioned bolt-cable combined support of large cross-section tunnel

To study the mechanical responses of large cross-section tunnel reinforced by pretensioned rock bolts and anchor cables, an analytical model is proposed. Considering the interaction between rock mass and bolt-cable support, the strain softening characteristic of rock mass, the elastic-plastic characteristic of bolt-cable support, and the delay effect of installation are considered in the model. To solve the different mechanical cases of tunneling reinforced by bolt-cable support, an analytical approach has been put forward to get the solutions of stress and displacement associated with tunneling. The proposed analytical model is verified by numerical simulation. Moreover, parametric analysis is performed to study the effects of pretension force,cross-section area, length, and supporting density of bolt-cable support on tunnel reinforcement, which can provide references for determining these parameters in tunnel design. Based on the analytical model, a new Ground Response Curve(GRC)considering the reinforcement of bolt-cable support is obtained, which shows the pretension forces and the timely installation are important in bolt-cable support. In addition, the proposed model is applied to the analysis of the Great Wall Station Tunnel, a high-speed railway tunnel with a super large cross-section, which shows that the analytical model of bolt-cable support was a useful tool for preliminary design of large cross-section tunnel.

Investigate the nonuniformity of low-energy electron beam with large cross-sections

Over the past decades, low-energy electron accelerators have been used worldwide for surface curing and sterilization. The beam nonuniformity is an important parameter of the low-energy electron beam with large cross-sections. A simple and accurate measurement system of nonuniformity for the low-energy electron beam with large cross-sections was developed. The main concept consists in the measurement of nonuniformity, which is realized by using a linear actuator to drive two scanning wires through the beam's cross-sections at a fixed speed. The beam distribution can be obtained by sending/collecting the current signals to/from the Data Acquisition (DAQ) software on a laptop by a USB DAQ card. This device is very convenient for the performance testing of a new accelerator at the manufacturer's site. The distribution of the homemade low voltage electron accelerator EBS-300-50 was measured and evaluated.

Full-band error control and crack-free surface fabrication techniques for ultra-precision fly cutting of large-aperture KDP crystals

Large-aperture potassium dihydrogen phos- phate （KDP） crystals are widely used in the laser path of inertial confinement fusion （ICF） systems. The most common method of manufacturing half-meter KDP crystals is ultra-precision fly cutting. When processing KDP crystals by ultra-precision fly cutting, the dynamic characteristics of the fly cutting machine and fluctuations in the fly cutting environment are translated into surface errors at different spatial frequency bands. These machin- ing errors should be suppressed effectively to guarantee that KDP crystals meet the full-band machining accuracy specified in the evaluation index. In this study, the anisotropic machinability of KDP crystals and the causes of typical surface errors in ultra-precision fly cutting of the material are investigated. The structures of the fly cutting machine and existing processing parameters are optimized to improve the machined surface quality. The findings are theoretically and practically important in the development of high-energy laser systems in China.

Minimal cut-based recursive decomposition algorithm for seismic reliability evaluation of lifeline networks

In this paper, a new probabilistic analytical approach, the minimal cut-based recursive decomposition algorithm （MCRDA）, is presented to evaluate the seismic reliability of large-scale lifeline systems. Based on the minimal cut searching algorithm, the approach calculates the disjoint minimal cuts one by one using the basic procedure of the recursive decomposition method. At the same time, the process obtains the disjoint minimal paths of the system. In order to improve the computation efficiency, probabilistic inequality is used to calculate a solution that satisfies the prescribed error bound. A series of case studies show that MCRDA converges rapidly when the edges of the systems have low reliabilities. Therefore, the approach can be used to evaluate large-scale lifeline systems subjected to strong seismic wave excitation.

砾砂地层盾构切削大直径群桩的刀具研究

刀盘刀具是盾构机实现切削功能并保证其顺利推进的主要部件,合适的刀具选型与设计在保证盾构机成功切削大直径钢筋混凝土群桩的过程中至关重要。依托沈阳地铁4号线盾构切桩工程,结合盾构穿越砾砂地层的工程特点以及切削大直径钢筋混凝土群桩的工程需求,对刀盘刀具进行选型,采用LS-DYNA软件模拟不同刃宽、刃角及前角的贝壳刀切削钢筋的效果。将分析结果应用于该工程,通过对比切桩前后既有隧道沉降变化规律论证刀具选型设计的合理性,并根据切桩后的贝壳刀磨损规律及盾构机排出钢筋情况,评估刀盘刀具切削效果,从而优化刀盘的刀具布置。研究结果表明:盾构刀盘采用面板+辐条复合式直角刀盘,切桩刀具采用前角-45°零后角、5 mm刃宽、90°刃角的双面刃贝壳刀,可提升盾构切桩效果;盾构切桩过程中既有隧道的变形波动控制在1.1 mm内,切桩完成后既有隧道的最大沉降仅为1.96 mm,未对既有隧道造成明显影响;刀盘布置贝壳刀时,应增加高度为210 mm的贝壳刀数量,尤其需要避免单个辐条上仅有1把高度为210 mm贝壳刀的情况,可有效提高刀盘刀具切削钢筋的能力并降低崩刃风险。刀具选型设计结果成功应用于沈阳地铁4号线切桩工程,可为今后类似工程提供参考。

基于点云数据的大型复杂钢结构智能化施工方法

大型复杂钢结构施工过程中,常面临施工尺寸质量难以把控、构件提升变形监测困难和合拢段现场配切效率低等问题。三维激光扫描技术可全覆盖地、快速精准地获取复杂构部件在施工过程中的点云数据,这为解决上述问题提供了新方法。为此,该文以重庆两江新区寨子路钢拱桥为工程背景,开展基于点云数据的大型复杂钢拱桥智能化施工方法的全流程研究。基于标靶球检测算法、快速四点一致集算法、迭代最近邻算法等实现标靶球点云数据的自动检测及多站点云数据之间的自动配准;通过BIM点云化技术、kNN算法等完成目标点云数据的半自动化提取,实现拱肋尺寸的智能化检测;基于八叉树算法、区域增长算法等实现拱肋提升变形的智能检测;为缩短拱肋的合拢工期,基于BIM模型焊缝信息提取技术、主成分分析算法、Canny边界检测算法、霍夫变换算法等提出数字化预拼装算法,得到合拢段的配切量。工程应用表明,该文所提出的智能施工方法效率高、自动化程度好,研究成果可为大型复杂钢结构的施工质量和安装效率的提升提供理论和算法支撑。

大应变切削中切削速度对纯铜纳米晶切屑微结构及性能的影响

大应变切削通过使工件材料受到刀刃的剪切和前刀面的挤压产生剧烈塑性变形从而形成高强度的超细晶切屑。采用有限元软件Deform-3D对纯铜进行大应变切削模拟,分析20°与-20°刀具前角下,切削速度对等效应变、等效应变速率和切削温度的影响规律。通过大应变切削试验,借助电子背散射衍射(EBSD)技术和维氏硬度检测等手段,对不同切削速度下纯铜切屑微观组织和力学性能进行了研究。实验结果表明:在正负前角下,随着切削速度增大,等效应变降低,等效应变速率和切削温度上升,且等效应变速率和切削温度受切削速度的影响更大;-20°刀具下得到的切屑晶粒尺寸主要分布在0.35μm以下,位错密度有明显下降趋势,硬度值由162.8HV减少至114.8HV,20°刀具下得到的晶粒尺寸主要分布在(0.2~0.6)μm之间,位错密度变化较小。硬度值由163.8HV减少至146.8HV;相比正前角,切削速度对负前角刀具制备的超细晶切屑在晶粒尺寸、位错密度和硬度方面具有更加剧烈的影响。

大振幅超声振动辅助高速干切装置设计开发与性能测试

超声换能器是超声振动辅助切削装置的核心部件,为研制适用于高速干切的大振幅超声振动辅助切削装置,需先设计研制超声换能器。基于考虑刀具的二级放大超声换能器设计方法,遵循“变幅杆-超声换能器”一体式设计理念,结合ANSYS有限元软件的模态分析和谐响应分析结果,设计并研制了二级放大超声换能器。根据研制的二级放大超声换能器特性,系统设计并研制与其相匹配的超声波发生器、止转环、输电系统和刀柄壳结构。对二级放大超声换能器进行了阻抗分析和振幅测量等性能测试。对所设计研制的大振幅超声振动辅助高速干切装置开展实验测试分析,探究了其对难加工材料30CrMnSiNi2A加工表面质量的改善程度。结果表明:二级放大超声换能器纵向振动仿真结果与理论设计一致,二级放大超声换能器输出振幅稳定,在50%输出功率下纵振振幅为15.4μm,最大可达25.1μm,且输出振幅与功率百分比呈正相关,性能良好;所研制的大振幅超声振动辅助切削装置可大幅降低进给方向切削力和表面粗糙度,显著提高难加工材料加工表面质量,适用于难加工材料高速干切。

切眼外错下孤岛工作面开采冲击危险性分析及防治措施

受矿井地质条件、开采布局及采掘接续不合理等影响,工作面布置时会留设孤岛工作面,严重影响矿井安全开采。为解决切眼外错下孤岛工作面开采冲击危险的难题,以高庄煤矿3_(上)1105孤岛工作面为例,采用理论分析、数值模拟、数据统计与分析相结合的研究方法,分析了孤岛工作面开采时覆岩结构特征、切眼外错区域应力分布规律以及巷道围岩稳定性。结果表明:切眼外错下3_(上)1105工作面开采期间超前支承应力峰值达到54.1 MPa,基于巷道围岩受力状态及变形量确定了冲击危险区域主要分布在3_(上)1107工作面切眼前后0~30 m范围。针对切眼外错区域采取了大直径钻孔卸压,通过现场监测及检验,微震、钻屑均未超过预警临界值,卸压解危效果良好。

松软破碎厚顶煤大跨度切眼变形破坏特征与控制技术

安阳主焦煤矿大断面切眼常采用被动支架沿顶布置,围岩变形量大、易漏冒,工人劳动强度大。针对上述问题,采用数值模拟方法研究了裂隙发育、位移和应力分布与切眼跨度之间的关系,提出了围岩控制策略和支护方案。结果表明,随着切眼跨度的增大,围岩塑性区范围逐渐增加,顶板以剪切滑移或拉剪破坏为主,两帮以泊松效应膨胀拉伸—剪切破坏为主;顶板下沉量、巷帮内挤和底鼓量均逐渐增大;顶煤、直接顶和基本顶部分岩层逐层渐次移动,顶板部分区域出现较大的裂隙,冒落拱以上深部顶板发生整体移动;巷道顶底板中有害拉伸应力区域范围呈现拱形分布,且逐渐增大。根据切眼围岩变形破坏特征,提出了高强度、高刚度、高预紧力的强力支护和被动单体液压支柱补强的主被动联合支护方法。现场工业性试验表明,切眼围岩得到了有效控制,可为类似裂隙发育托顶煤大断面切眼围岩控制提供参考。

沿空留巷动压区锚索主动支护技术研究

为解决车集煤矿深部工作面高矿压条件下沿空留巷变形严重问题,根据2611工作面生产地质资料,采用经验计算和FLAC^(3D)数值模拟等方法开展矿压分析、大直径锚索主动支护数值模拟,由结果可知,车集煤矿2611工作面锚杆+普通锚索+大直径锚索加强支护手段支护效果远优于其他支护形式。通过工程实践:2611下巷沿空留巷动压段超前支承压力影响范围约50 m,工作面后约150 m,沿空留巷切顶卸压大直径锚索主动支护技术,适用于车集煤矿深部工作面沿空留巷支护,能够有效控制围岩应力,将巷道变形控制在合理范围内。

折线大斜切挑坎水力特性研究

斜切挑坎多被用于泄水建筑物轴线与天然河道互成夹角的工程。然而,当下游河道过于狭窄时,斜切挑坎无法满足水流归槽及消能防冲的要求。为此,在斜切挑坎的基础上提出折线大斜切挑坎。通过模型试验的方法,测量不同折线大斜切挑坎体型在不同来流条件下,挑射水流的扩散情况和下游水垫塘内的底板压力分布,以研究折线大斜切挑坎的水力特性。结果表明:相较于传统斜切挑坎,折线大斜切挑坎既可以实现对挑流水舌水量和入水范围的灵活调整,也可以缓解水垫塘压力分布的不均匀现象。研究结果可为折线大斜切挑坎的工程设计和应用提供一定的参考。