Numerical Studies on Chip Formation in Drag-Pick Cutting of Rocks

A two dimensional non-linear finite element simulation model has been developed using a mathematical model for progressive rock failure for understanding the mode and sequence of rock failure under a drag pick cutter. Rock cutting simulation has also been done using linear elastic modeling using local stability factor contouring. It has been observed from the simulation results that during negative rake angle cutting the chipping occurs by shear failure of the elements. Whereas, in positive rake angle cutting, some elements were observed to fail in shear and some under tension. The predicted peak cutting force using the developed models was found to be up to 25% higher than the experimental values. The effect of input parameters such as rake angle, flank wear, depth of cut and rock properties on the predicted peak cutting force has been studied, verified from earlier experimental studies and compared with some earlier proposed theories on rock cutting. The elastic stress analysis model based on the stability factor contouring method has also been found to be an effective tool to bracket the expected peak cutting force for a given operational and rock parameters but failed to simulate the effect of pick geometry (rake angle) correctly. The non-linear simulation model using progressive rock element failure is superior to elastic linear stress analysis model by simulating the correct trends for all the rock and machining parameters.