Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency
Rock-breaking cutters are critical components in tunneling, mining, and drilling operations, where efficiency, durability, and energy consumption are paramount. Traditional cutter designs and empirical process optimization methods often fail to address the dynamic interaction between heterogeneous r...
Saved in:
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-06-01
|
| Series: | Computation |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2079-3197/13/7/152 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849733600857030656 |
|---|---|
| author | Yuecao Cao Qiang Zhang Shucheng Zhang Ying Tian Xiangwei Dong Xiaojun Song Dongxiang Wang |
| author_facet | Yuecao Cao Qiang Zhang Shucheng Zhang Ying Tian Xiangwei Dong Xiaojun Song Dongxiang Wang |
| author_sort | Yuecao Cao |
| collection | DOAJ |
| description | Rock-breaking cutters are critical components in tunneling, mining, and drilling operations, where efficiency, durability, and energy consumption are paramount. Traditional cutter designs and empirical process optimization methods often fail to address the dynamic interaction between heterogeneous rock masses and tool structures, leading to premature wear, high specific energy, and suboptimal performance. Topology optimization, as an advanced computational design method, offers transformative potential for lightweight, high-strength cutter structures and adaptive cutting process control. This review systematically examines recent advancements in topology-optimized cutter design and its integration with rock-cutting mechanics. The structural innovations in cutter geometry and materials are analyzed, emphasizing solutions for stress distribution, wear/fatigue resistance, and dynamic load adaptation. The numerical methods for modeling rock–tool interactions are introduced, including discrete element method (DEM) simulations, smoothed particle hydrodynamics (SPH) methods, and machine learning (ML)-enhanced predictive models. The cutting process optimization strategies that leverage topology optimization to balance objectives such as energy efficiency, chip formation control, and tool lifespan are evaluated. |
| format | Article |
| id | doaj-art-992176b98cc8465ca67a17078aacb0ab |
| institution | DOAJ |
| issn | 2079-3197 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Computation |
| spelling | doaj-art-992176b98cc8465ca67a17078aacb0ab2025-08-20T03:08:00ZengMDPI AGComputation2079-31972025-06-0113715210.3390/computation13070152Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process EfficiencyYuecao Cao0Qiang Zhang1Shucheng Zhang2Ying Tian3Xiangwei Dong4Xiaojun Song5Dongxiang Wang6College of Mechanical Engineering, Liaoning Technical University, Fuxin 123000, ChinaCollege of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266580, ChinaCollege of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266580, ChinaCollege of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266580, ChinaCollege of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266580, ChinaXi’an Heavy Equipment Tongchuan Coal Mining Machinery Co., Ltd., Loudi 417099, ChinaCollege of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266580, ChinaRock-breaking cutters are critical components in tunneling, mining, and drilling operations, where efficiency, durability, and energy consumption are paramount. Traditional cutter designs and empirical process optimization methods often fail to address the dynamic interaction between heterogeneous rock masses and tool structures, leading to premature wear, high specific energy, and suboptimal performance. Topology optimization, as an advanced computational design method, offers transformative potential for lightweight, high-strength cutter structures and adaptive cutting process control. This review systematically examines recent advancements in topology-optimized cutter design and its integration with rock-cutting mechanics. The structural innovations in cutter geometry and materials are analyzed, emphasizing solutions for stress distribution, wear/fatigue resistance, and dynamic load adaptation. The numerical methods for modeling rock–tool interactions are introduced, including discrete element method (DEM) simulations, smoothed particle hydrodynamics (SPH) methods, and machine learning (ML)-enhanced predictive models. The cutting process optimization strategies that leverage topology optimization to balance objectives such as energy efficiency, chip formation control, and tool lifespan are evaluated.https://www.mdpi.com/2079-3197/13/7/152topology optimizationrock-breaking cutterrock-cutting mechanicsstructural designnumerical simulationenergy efficiency |
| spellingShingle | Yuecao Cao Qiang Zhang Shucheng Zhang Ying Tian Xiangwei Dong Xiaojun Song Dongxiang Wang Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency Computation topology optimization rock-breaking cutter rock-cutting mechanics structural design numerical simulation energy efficiency |
| title | Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency |
| title_full | Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency |
| title_fullStr | Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency |
| title_full_unstemmed | Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency |
| title_short | Optimization of Rock-Cutting Tools: Improvements in Structural Design and Process Efficiency |
| title_sort | optimization of rock cutting tools improvements in structural design and process efficiency |
| topic | topology optimization rock-breaking cutter rock-cutting mechanics structural design numerical simulation energy efficiency |
| url | https://www.mdpi.com/2079-3197/13/7/152 |
| work_keys_str_mv | AT yuecaocao optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency AT qiangzhang optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency AT shuchengzhang optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency AT yingtian optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency AT xiangweidong optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency AT xiaojunsong optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency AT dongxiangwang optimizationofrockcuttingtoolsimprovementsinstructuraldesignandprocessefficiency |