Experimental research and energy analysis of a new type of dry ice powder pneumatic rock breaking technology

When the traditional drill and blast method is applied to rock crushing projects,it has strong vibration,loud noise and dust pollution,so it cannot be used in densely populated areas such as urban public works.We developed a supercritical CO_(2)true triaxial pneumatic rock-breaking experimental system,and conducted laboratory and field tests of dry ice powder pneumatic rock-breaking.The characteristics of the blast-induced vibration velocity waveform and the evolution of the vibration velocity and frequency with the focal distance were analyzed and discussed.The fracturing mechanism of dry ice powder pneumatic rock breaking is studied.The research results show that:(1)The vibration velocity induced by dry ice powder pneumatic rock breaking decays as a power function with the increase of the focal distance;(2)The vibration frequency caused by dry ice powder pneumatic rock breaking is mainly distributed in 1–120 Hz.Due to the dispersion effect,the dominant frequency of 10–30 Hz appears abnormally attenuated;(3)The traditional CO_(2)phase change fracturing energy calculation formula is also applicable to dry ice pneumatic rock breaking technology,and the trinitrotoluene(TNT)equivalent of fracturing energy is applicable to the Sadovsky formula;(4)Dry ice powder pneumatic rock breaking is shock wave and highenergy gas acting together to fracture rock,which can be divided into three stages,among which the gas wedge action of high-energy gas plays a dominant role in rock mass damage.

Rock breaking performance of the newly proposed unsubmerged cavitating abrasive waterjet

To improve the rock breaking ability, cavitating waterjet and abrasive waterjet are combined by using a coaxial low-speed waterjet generated around the periphery of a high-speed abrasive waterjet, and a new type of waterjet called unsubmerged cavitating abrasive waterjet(UCAWJ) is thus produced. The rock breaking performance of UCAWJ was compared with submerged cavitating abrasive waterjet(SCAWJ)and unsubmerged abrasive waterjet(UAWJ) by impinging sandstone specimens. Moreover, the effects of jet pressure, standoff distance, abrasive flow rate and concentration were studied by evaluating the specific energy consumption, and the area, depth, and mass loss of the eroded specimen. The results show that the artificially generated submerged environment in UCAWJ is able to enhance the rock breaking performance under the same operating parameters. Furthermore, the rock breaking performance of UCAWJ is much better at higher jet pressures and smaller standoff distances when compared with UAWJ. The greatest rock breaking ability of UCAWJ appears at jet pressure of 50 MPa and standoff distance of 32 mm, with the mass loss of sandstone increased by 370.6% and the energy dissipation decreased by 75.8%. In addition, under the experimental conditions the optimal abrasive flow rate and concentration are 76.5 m L/min and 3%, respectively.

Comparative Study of the Rock-breaking Mechanism of a Disc Cutter and Wedge Tooth Cutter by Discrete Element Modelling

The operation of a shield tunnel boring machine(TBM)in a high-strength hard rock stratum results in significant cutter damage,adversely affecting the thrust and torque of the cutter head.Therefore,it is very important to carry out the research on the stress characteristics and optimize the cutter parameters of cutters break high-strength hard rock.In this paper,the rock-breaking performance of cutters in an andesite stratum in the tunnel of Qingdao Metro Line No.8 was investigated using the discrete element method and theoretical analysis.The rock-breaking processes of a disc cutter and wedge tooth cutter were simulated by software particle flow code PFC^(3D),and the rock-breaking degree,stress of the cutter,and rock-breaking specific energy were analyzed.The rock damage caused by the cutter in a specific section was divided into three stages:the advanced influence,crushing,and stabilizing stages.The rock-breaking degree and the tangential and normal forces of the wedge tooth cutter are larger than that of the disc cutter under the same conditions.The disc cutter(wedge tooth cutter)has the highest rock-breaking efficiency at a cutter spacing of 100 mm(110 mm)and a penetration depth of 8 mm(10 mm),and the rock-breaking specific energy is 11.48 MJ/m^(3)(12.05 MJ/m^(3)).Therefore,two types of cutters with different penetration depths or cutter spacing should be considered.The number of teeth of wedge tooth cutters can be increased in hard strata to improve the rock-breaking efficiency of the shield.The research results provide a reference for shield cutterhead selection and cutter layout in similar projects.

Differentiation and analysis on rock breaking characteristics of TBM disc cutter at different rock temperatures

In order to study rock breaking characteristics of tunnel boring machine(TBM) disc cutter at different rock temperatures,thermodynamic rock breaking mathematical model of TBM disc cutter was established on the basis of rock temperature change by using particle flow code theory and the influence law of interaction mechanism between disc cutter and rock was also numerically simulated.Furthermore,by using the linear cutting experiment platform,rock breaking process of TBM disc cutter at different rock temperatures was well verified by the experiments.Finally,rock breaking characteristics of TBM disc cutter were differentiated and analyzed from microscale perspective.The results indicate the follows.1) When rock temperature increases,the mechanical properties of rock such as hardness,and strength,were greatly reduced,simultaneously the microcracks rapidly grow with the cracks number increasing,which leads to rock breaking load decreasing and improves rock breaking efficiency for TBM disc cutter.2) The higher the rock temperature,the lower the rock internal stress.The stress distribution rules coincide with the Buzin Neske stress circle rules: the maximum stress value is below the cutting edge region and then gradually decreases radiant around; stress distribution is symmetrical and the total stress of rock becomes smaller.3) The higher the rock temperature is,the more the numbers of micro,tensile and shear cracks produced are by rock as well as the easier the rock intrusion,along with shear failure mode mainly showing.4) With rock temperature increasing,the resistance intrusive coefficients of rock and intrusion power decrease obviously,so the specific energy consumption that TBM disc cutter achieves leaping broken also decreases subsequently.5) The acoustic emission frequency remarkably increases along with the temperature increasing,which improves the rock breaking efficiency.

The rock breaking and ROP increase mechanisms for single-tooth torsional impact cutting using DEM

Torsional impact drilling is a new technology which has the advantages of high rock-breaking efficiency and a high rate of penetration(ROP).So far,there is no in-depth understanding of the rock-breaking mechanism for the ROP increase from torsional impact tools.Therefore,it has practical engineering significance to study the rock-breaking mechanism of torsional impact.In this paper,discrete element method(DEM)software(PFC2 D)is used to compare granite breaking under the steady and torsional impacting conditions.Meanwhile,the energy consumption to break rock,microscopic crushing process and chip characteristics as well as the relationship among these three factors for granite under different impacting frequencies and amplitudes are discussed.It is found that the average cutting force is smaller in the case of torsional impact cutting(TIC)than that in the case of steady loading.The mechanical specific energy(MSE)and the ratio of brittle energy consumption to total energy are negatively correlated;rock-breaking efficiency is related to the mode of action between the cutting tooth and rock.Furthermore,the ROP increase mechanism of torsional impact drilling technology is that the ratio of brittle energy consumption under the TIC condition is larger than that under a steady load;the degree of repeated fragmentation of rock chips under the TIC condition is lower than that under the steady load,and the TIC load promotes the formation of a transverse cracking network near the free surface and inhibits the formation of a deep longitudinal cracking network.

Effect of the number of irradiation holes on rock breaking under constant laser energy

The use of mechanical drilling in accessing energy resources stored in deep and hard rock formations is becoming increasingly challenging.Thus,laser irradiation has emerged as a novel drilling method with considerable in this context.This study examines the variation of rock fracture length,fracture tortuosity,hole size,and rock breaking efficiency for a different number of holes and laser power,based on the constant total energy of laser irradiation.As indicated by the results,increasing the laser power increases the laser intensity,which helps increase the hole diameter and depth.Moreover,for the same laser power,increasing the number of irradiated holes reduces the laser energy absorbed by each hole,which is not conducive to increasing the hole depth.As the number of holes increases,the mass loss of the rock also increases,while both specific energy(SE)and modified specific energy(MSE)decrease.When the number of holes remains the same,the mass of the shale removed by low power is less than that removed by high power,while SE and MSE have an inverse relation with power.Therefore,high laser power and multiple-hole irradiation are more conducive to rock breaking.Besides,the fracture length and fracture tortuosity of the rock irradiated by the low laser power will increase first and then decrease with the increase in the number of holes,and reach the peak value when the irradiation takes place through three holes.When a high-power laser irradiates the rock,the fracture length and tortuosity will increase with the increase in the number of irradiation holes.This is because a rock irradiated by low power dissipates more energy,with the result that the energy absorbed by the sample with four irradiation holes is not enough to break the rock quickly.This study is expected to provide some guidance to break rock for drilling deep reservoirs and hard rock formations using laser irradiation.

New Method for Studying Rock-Breaking Mechanism by Disc Cutters

Gaining a thorough understanding of the theoretical principles of rock breaking with a disc cutter is a critical issue in tunnel boring machine(TBM) technology.To fully consider the complexity and importance of the basic principles of rock breaking during tunnel excavation,in this paper we use a new method, the smooth particle hydrodynamics(SPH), to study the rock-breaking mechanism and verify its accuracy and feasibility. Using the SPH method, we induce the rock fragmentation process with two cutters in synchronous and sequential orders. The results show that when the cutters act on rock sequentially,the second indentation influences the crack evolution of the first indentation. With increased cutter spacing, the second crack gradually becomes independent of the first crack.Under synchronous action of the two cutters, a bursiform nucleus is generated beneath the cutters and the area of the nucleus increases with increased cutter spacing. Whether the cutters act on the rock sequentially or synchronously,we found the optimum cutter spacing of our chosen rock type to be 60 mm. Our analyses results show that the efficiency of sequential rock cutting is superior to synchronous cutting, both with respect to crack evolution and cutter force.

Rock Breaking Performance of a Pick Assisted by High-pressure Water Jet under Different Configuration Modes

In the process of rock breaking, the conical pick bears great cutting force and wear, as a result, high-pressure water jet technology is used to assist with cutting. However, the effect of the water jet position has not been studied for rock breaking using a pick. Therefore, the models of rock breaking with different configuration modes of the water jet are established based on SPH combined with FEM. The effect of the water jet pressure, distance between the jet and the pick bit, and cutting depth on the rock breaking performance as well as a comparison of the tension and compression stress are studied via simulation; the simulation results are verified by experiments. The numerical and experimental results indicate that the decrease in the rates of the pick force obviously increases from 25 MPa to 40 MPa, but slowly after 40 MPa, and the optimal distance between the jet and the pick bit is 2 mm under the JFP and JSP modes. The JCP mode is proved the best, followed by the modes of JRP and JFP, and the worst mode is JSP. The decrease in the rates of the pick force of the JCP, JRP, JFP, and JSP modes are up to 30.96%, 28.96%, 33.46%, 28.17%, and 25.42%, respectively, in experiment. Moreover, the JSP mode can be regarded as a special JFP model when the distance between the pick-tip and the jet impact point is 0 mm. This paper has a dominant capability in introducing new numerical and experimental method for the study of rock breaking assisted by water jet and electing the best water jet position from four different configuration modes.

Flow structure and rock-breaking feature of the self-rotating nozzle for radial jet drilling

For improving the hole-enlarging capability,roundness and rock-breaking efficiency of the nozzle in radial jet drilling,a new structure of self-rotating nozzle was put forward.The flow structure and rock-breaking features of the self-rotating nozzle were investigated with sliding mesh model and labortary tests and also compared with the straight and the swirling integrated nozzle and multi-orifice nozzle which have been applied in radial jet drilling.The results show that the self-rotating jet is energy concentrated,has longer effective distance,better hole-enlarging capability and roundness and impacts larger circular area at the bottom of the drilling hole,compared with the other two nozzles.Forward jet flow generated from the nozzle is peak shaped,and the jet velocity attenuates slowly at the outer edge.Due to periodic rotary percussion,the pressure fluctuates periodically on rock surface,improving shear and tensile failures on the rock matrix and thereby enhancing rock-breaking efficiency.The numerical simulation results of the flow structure of the nozzle are consistent with the experiments.This study provides an innovative approach for radial jet drilling technology in the petroleum industry.

Vibrating-Rocking Motion of Caisson Breakwater Under Breaking Wave Impact

The possible motions of a caisson breakwater under dynamic load excitation include vibrating, vibrating-sliding andvibrating-rocking motions. The models of vibrating motion and vibrating-sliding motion have been proposed in an earlypaper. In this paper, a model of vibrating-rocking motion of caisson breakwaters under breaking wave impact is presented, which can be used to simulate the histories of vibrating-rocking motion of caisson breakwaters. The effect of rocking motion on the displacement, rotation, sliding force and overturning moment of breakwaters is investigated. In casethe overturning moment exceeds the stability moment ofa caisson, the caisson may only rock. The caisson overturns only in case the rocking angle exceeds the critical angle. It is shown that the sliding force and overturning moment of break-waters can be reduced effectively due to the rocking motion. It is proposed that some rocking motion should be allowedin breakwater design.

A swirling jet from a nozzle with tangential inlets and its characteristics in breaking-up rocks

In order to apply a swirling jet to a PDC drill bit, the nozzle performance influenced by nozzle inlet geometric parameters and rock breaking tests under submerged conditions were studied. Numerical simulation was used to study the influence of the nozzle structure on the swirling intensity and nozzle discharge coefficient. Simulation results indicate that spreading angle of the swirling jet is greater than that of the non-swirling jet, and the swirling intensity of the jet is strongly influenced by the length of the nozzle body but weakly by the number of tangential inlets. Rock breaking tests were conducted to evaluate the performance of the swirling jet. It is found that the swirling jet shows a lower threshold pressure to break the rock samples and could break rock more efficiently compared with the non-swirling jet.

Numerical Study on Rock Breaking Mechanism of Supercritical CO_(2)Jet Based on Smoothed Particle Hydrodynamics

Supercritical carbon dioxide(Sc-CO_(2))jet rock breaking is a nonlinear impact dynamics problem involving many factors.Considering the complexity of the physical properties of the Sc-CO_(2)jet and the mesh distortion problem in dealing with large deformation problems using the finite element method,the smoothed particle hydrodynamics(SPH)method is used to simulate and analyze the rock breaking process by Sc-CO_(2)jet based on the derivation of the jet velocity-density evolution mathematical model.The results indicate that there exists an optimal rock breaking temperature by Sc-CO_(2).The volume and length of the rock fracture increase with the rising of the jet temperature but falls when the jet temperature exceeds 340 K.With more complicated perforation shapes and larger fracture volumes,the Sc-CO_(2)jet can yield a rock breaking more effectively than water jet,The stress analysis shows that the Sc-CO_(2)rock fracturing process could be reasonably divided into three stages,namely the fracture accumulation stage,the rapid failure stage,and the breaking stabilization stage.The high diffusivity of Sc-CO_(2)is identified as the primary cause of the stress fluctuation and W-shaped fracture morphology.The simulated and calculated results are generally in conformity with the published experimental data.This study provides theoretical guidance for further study on Sc-CO_(2)fracturing mechanism and rock breaking efficiency.

Analysis of the Flow Field Characteristics Associated with the Dynamic Rock Breaking Process Induced by a Multi-Hole Combined External Rotary Bit

The characteristics of the flow field associated with a multi-hole combined external rotary bit have been studied by means of numerical simulation in the framework of an RNG k-εturbulence model,and compared with the results of dedicated rock breaking drilling experiments.The numerical results show that the nozzle velocity and dynamic pressure of the nozzle decrease with an increase in the jet distance,and the axial velocity of the nozzle decays regularly with an increase in the dimensionless jet distance.Moreover,the axial velocity related to the nozzle with inclination angle 20°and 30°can produce a higher hole depth,while the radial velocity of the nozzle with 60°inclination can enlarge the hole diameter.The outcomes of the CFD simulations are consistent with the actual dynamic rock breaking and pore forming process,which lends credence to the present results and indicates that they could be used as a reference for the future optimization of systems based on the multi-hole combined external rotary bit technology.

VIBRATING-UPLIFT ROCKING MOTION OF CAISSONBREAKWATERS UNDER VARIOUS BREAKINGWAVE IMPACT FORCES

Overturning is one of principal failure types of caisson breakwaters and is an essential content of stability examination in caisson breakwater design. The mass-spring-dashpot model of caisson-foundation system is used to simulate the vibrating-uplift rocking motion of caisson under various types of breaking wave impact forces, i.e., single peak impact force, double peak impact force, and shock-damping oscillation impact force. The effects of various breaking wave types and the uplift rocking motion on dynamic response behaviors of caisson breakwaters are investigated. It is shown that the dynamic responses of a caisson are significantly different under different types of breaking wave impact forces even when the amplitudes of impact forces are equal. Though the rotation of a caisson is larger due to the uplift rocking motion, the displacement, the sliding force and the overturning moment of the caisson are significantly reduced. It provides the theoretical base for the design idea that the uplift rocking motion of caisson is allowed in design.

AN EXPERIMENTAL STUDY ON THE MECHANISM AND PROCESS OF ROCK BREAKAGE WITH THE PLANETARY CUTTER HEAD

Based on the kinematic features of the Planetary Cutter Head (PCH),this paper deals with specificity of rock breakago with PCH, and the basic laws of this process are presented, The study shows that the axial force acting on the drilling face by a single cutter and the uniaxial compressive strength of the drilled rock have the marked influence on the penetrating depth of the cutter ,and the breakage of the drilling face with the PCH has two forms,the cyclical and the noncyclical. The major reason why the PCH has higher drilling efficiency than other cutter heads is that the PCH can make more free faces on the drilling face.

非刀具破岩理论与技术研究进展与趋势

随着我国深地战略的逐步实施,深部资源开采和地下空间建设迎来新的机遇,但也面临诸多挑战,高地应力、高地温和坚硬岩体等极端地质条件层出不穷。岩石破碎技术是所有资源开采和地下空间建设的主要工程活动,是决定施工工艺和工程效率的主要因素。在极端地质条件下,以刀具为基础的岩石破碎技术由于刀具磨损快、岩石破碎效率低,已成为遏制深地战略顺利实施的关键技术瓶颈,为解决深地岩石高效破碎难题,保障深地战略的顺利实施,迫切需求革命性的岩石破碎技术。无刀具破岩技术作为刀具破岩技术的重要补充,是突破刀具破岩技术瓶颈的可行性思路。为此,将无刀具破岩技术归纳为冲击破岩、热应力破岩和冲蚀磨损破岩3类技术体系,系统分析了水射流、激光和磨料空气射流等16种岩石破碎技术,总结了每种技术的发展历史和技术原理,分析了其破岩优势和技术瓶颈。得出,目前非刀具破岩技术没有在资源开采和地下空间建设中广泛应用的主要原因为破岩能耗高、适用较差和技术装备复杂等。相比刀具破岩,非刀具破岩技术破岩能量利用率较低,水射流破岩比能耗为刀具的40~70倍。微波、激光和等离子体等技术对施工环境要求较高,无法适用于钻井、隧道掘进等受限和恶劣环境。为解决极端地质条件岩石破碎难题,提出多种非刀具破岩技术协同破岩的思路,充分发挥每一种非刀具破岩的技术优势,构建了以射流切缝卸除高地应力、粒子冲击体积破碎坚硬岩体的破岩理念,最大限度降低岩石破碎能耗,简化系统装备,为岩石破碎技术向非刀具化发展提供理论支撑。

围压条件下粒子冲击破岩裂隙扩展机理研究

为揭示粒子冲击下围压对岩石裂隙形成及扩展机制的影响,开展了粒子冲击破岩试验和微纳米工业CT(compnted tomography)扫描试验,明确了围压对粒子冲击作用下岩石裂隙扩展特征的影响;并对不同围压条件下的粒子冲击进行数值模拟,分析了岩石的应力场和裂隙场演化过程,揭示了围压影响裂隙扩展的内在机制。结果表明,粒子冲击岩石后,在岩石内部形成破碎区和晶间主裂隙扩展区。压应力导致形成的剪切应力和拉应力是破碎区形成的主要原因,而晶间主裂隙扩展区形成的主要原因是切向衍生拉应力。围压使岩石颗粒间产生预应力,导致切向衍生拉应力需克服颗粒之间的初始压应力才能形成张拉裂隙;围压的增大导致岩石颗粒间剪切裂隙比例和摩擦效应提升,产生相同裂隙数目消耗能量增大,抑制了晶间主裂隙扩展区和破碎区的形成,破碎效果降低。

预切缝位置及深度对SBM滚刀破岩的影响

利用水射流对岩体进行预切缝是提高竖井全断面掘进机破岩效率、实现深部资源机械化开发的关键技术。针对预切缝位置及深度合理参数选取的难题,首先指出了锥面刀盘带动下滚刀破岩的工况特征,进而基于Cohesive单元方法,建立了预切缝条件下的滚刀破岩离散-连续耦合数值模型。以完整岩体为对照组,对比分析了不同预切缝距离和深度对滚刀破岩的受力特征和岩石破碎特征的影响规律。阐述了预切缝条件下,滚刀破岩时密实核形成、块状岩渣形成、Hertz裂纹扩展3个阶段性特征,指出了岩体的非对称破碎特性和不同区域岩渣的形成机制。最终从滚刀受力、破岩面积、破岩比能耗、岩渣破碎程度4个方面综合分析,确定了预切缝的最佳距离和深度取值范围。研究结果表明:预切缝可以显著减小竖井全断面掘进机滚刀破岩过程中的贯入力和侧向力。与完整岩体相比,贯入力峰值降低了44.0%~10.3%。侧向力峰值降低了35.2%~6.5%。预切缝间距及深度较小时,会限制滚刀破岩范围,同时使得破碎岩体块度更小,导致破岩比能耗增高。随着预切缝深度的增大,破岩体积先增大后趋于稳定,比能耗先减小后保持不变。最终,确定了切缝距离为70~90 mm,深度为60~80 mm时破岩效果最佳,破岩体积较无切缝时提高约1倍,破岩比能耗降低69.2%。研究结果为刀盘辅助破岩装备的设计及参数确定提供了参考。

钢粒子迟滞重复冲击破岩硬岩损伤破裂特征研究

粒子冲击辅助破岩技术凭借其快速、高效等优点,对硬质岩体有着较好的破岩效果。通过粒子冲击试验和离散元模拟相结合的方法研究单、双粒子冲击速度、双粒子间距等因素对高强度花岗岩表面、三维及剖面形貌特征的影响,探寻冲击坑深度、冲击坑体积及冲击坑表面面积随冲击参数的变化规律,统计粒子冲击破岩裂纹的分布规律,并且从能量吸收率的角度评价双粒子迟滞冲击破岩的效能。结果表明:冲击坑深度与冲击速度呈正相关;随着粒子间距的增大,冲击坑由相交逐渐相离,形貌随之变化,冲击坑体积随之减小,而冲击坑表面面积增大;通过模拟发现,裂纹主要分布在斜长石与钾长石的晶界处,以拉伸破坏为主;当选用5mm直径的钢粒子破碎强度200MPa左右的极坚硬花岗岩时,双粒子迟滞冲击破岩的能量吸收率曲线随粒子冲击速度增大趋于平缓,在双粒子迟滞冲击破岩的粒子间距为8~10 mm且冲击速度400 m/s左右时能达到最佳的冲击辅助破岩效果。