The Analysis of Cuttability Properties of Model Samples Prepared with Different Strength

Niyazi Bilim and Bilgehan Keke

Selcuk University, Mining Engineering Department, Konya, Turkey

Abstract. Energy saving is very important parameter in the industry. Rock excavation (cutting) machines represent a major cost item in the mining and tunnel sector. Therefore, determining the optimum cutting conditions is major importance in the sector. Otherwise prediction of the performance and selecting of the rock cutting machines is very important. In literature, there are studies usually related to the prediction of cutting performance referring to materials with adjustable properties. Specific energy is defined as the amount of energy required to cut a unit volume of rock. In this study, rock cutting experiments were performed on eight concrete samples which indicates model rock samples in-situ with small scale linear cutting machine. During the cutting the specific energy value was calculated from the electric energy required of machine was measured by using power analyzer. In addition, physical and mechanical properties of the model concrete blocks were determined then relationships between specific energy values obtained from cutting tests and the model samples mechanical properties were analyzed. In this study, concrete samples with different concrete class were used owing to heterogeneous properties of concretes. Thus, mechanical properties of samples were adjusted as required. Eight different concrete samples with using EN 206-1 standard C8/10, C12/15, C16/20, C20/25, C25/30, C30/37, C35/45, C40/50 concrete class were used as model specimens. These specimens were cut same condition and calculated specific energies of samples. In addition, some mechanical properties were carried out on these specimens with different concrete class. In conclusion, the relation between specific energy and mechanical properties of samples were determined. Keywords: Cuttability, performance prediction, cutting theory, specific energy.

1 Introduction
Excavation cost is very high in mining and similar operations. Rock excavation (cutting) machines represent a major cost item in the mining and tunnel sector. Therefore, determining the optimum cutting conditions is major importance in the sector. Otherwise, prediction of the performance and selecting of the rock cutting machines is very important. The rock cutting tests carried out in the laboratory is
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also the most successful, reliable and efficient method to observe tool rock interaction and estimate the tool forces [1]. Balc et al. [2] rock cutting test carried out on rock samples, mineral and ore samples with different mechanical properties. They used both the full-scale cutting tests and the small scale rock cutting tests. Also, they analyzed to the relation between specific energy and physical and mechanical properties of rocks as statistically. Fowell and McFeatSmith [3, 4] performed experimental studies to correlate specific energy obtained by the small scale rock cutting tests to some rock properties such as cone indenter index, cementation coefficient, Schmidt hammer rebound value and compressive strength. Specific energy is one of the parameters that describe the cutting efficiency in laboratory and in field. In mechanical excavation studies, some rock properties affecting the SE were investigated by different researchers [5, 6]. But, the estimation of the cutting efficiency by using a single rock property is impossible. Since many rock properties affect the cuttability of rocks specific energy values were correlated, in the past, with rock properties by different researchers [4, 11]. Bilim [12] calculated to specific energy (kWh/m), amount of excavation (m/h), and feed rate (m/dk) values for performing analyses of cutting machines in

ayrhan coal mining and derived to mathematical model for estimation of specific energy. Copur et al. [13] searched for relations between optimum specific energy obtained by the full-scale cutting tests and laboratory tests included compressive and tensile strength, they also looked for relations between a brittleness index obtained from macro-scale indentation tests and rock cutting efficiency, including specific energy and cutter forces. Cuttability is very important parameter for tunnel and ore excavation. Cuttability are affected by many parameters. However, the most important parameter affected to rock cuttability is rock properties. The most effective parameter of rock properties can be regarded as mechanical properties of the rocks. Therefore, in this study, it is aimed that mechanical properties of the rock is determined to the effect on rock cuttability. Also, it is planned to derive a mathematical equation for practically estimation of rock cuttability. In accordance with this purpose, the tests were carried out by preparing model rock samples. In this study, rock cutting experiments were performed on different seven model samples with small scale linear cutting machine during the cutting the specific energy value was calculated from using with load cell. In addition, physical and mechanical properties of model samples were determined. Relationships between specific energy values obtained from cutting tests and model samples mechanical properties were analyzed.

2 Preparation of Model Samples

Many study carried out for estimation of cutting machine performance and cuttability have been carried out to cutting tests in the laboratory on different rock samples. Hence, estimation models derived for estimation of cuttability give
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accurate results at similar rocks used in the tests. Thus, there is no definitive accepted model for estimation of rock cuttability, nowadays. The biggest cause of this condition is heterogeneous of rock units. In other words, rock units have many parameters affecting to cuttability. To derive accurate model for heterogeneous rock units, an estimation model including whole parameters affecting to cuttability is required. For example, there are good estimation models accepted by scientist for heterogeneous rock mass in mining (RMR and Q etc.). These models have been formed by using many parameters determining rock mass properties to analyze of rock mass and good results have been obtained. If an estimation model is formed by evaluating many parameters affecting cuttability, this model will be very useful. However, a sophisticated study carried out for estimation of rock cuttability is required to effort, time and cost. It may be appropriate in large project such as a tunnel project excavated with TBM. Eventually, the models to be derived for estimation of rock cuttability can be performed easily by scientist and it should require less effort. With all this information, these studies were conducted to derive an estimation model by using two different properties affecting rock cuttability. The model samples for cutting tests have been prepared in concrete classes that stated in EN-206-1 test Standard. Different cement, water and aggregate ratio have been prepared for each concrete class. The aim of this is to form model samples in different endurance properties. 5 cube samples have been prepared from each concrete class, so 35 cube concrete samples have been prepared in total. All of model samples are 7*7*7 cm. these model samples have been firstly left in water along 28 days. Later, tests have been started. As shown in Fig. 1 preparations of model samples.
Fig. 1 Preparation of model samples 274 N. Bilim and B. Keke

3 Mechanical Properties of Model Samples

Uniaxial compressive strength (UCS) and Schmidt hardness tests carried out on the model samples. Then, the results as shown in Table 1.
Table 1 Mechanical test results of model samples

Concrete class Test Results UCS (MPa) Schmidt Hardness Density (gr/cm3) C12/15 18.7 21.5 2.35 C16/20 22.1 22.7 2.35 C20/25 30.2 24.6 2.40 C25/30 41.9 32 2.40 C30/37 50.2 32.3 2.39 C35/45 48.5 32.5 2.37 C40/50 55.9 33.4 2.38

4 Cutting Tests and Determining of Cutting Energy 4.1 Linear Cutting Tests
The small-scale cutting test is discussed in detail by McFeat and Fowell [3, 4 and 7]. The test results are classified as index values and evaluated according to previously accumulated field performance data. The basic disadvantage of this test is that the predictions using this method are based on an index cutter instead of a real life cutter. This test has been developed by McFeat Smith and Fowell [3] and then using Bilgin and Shariar [14] to simulate the cutting action of chisel tools and to measure the corresponding cutting properties of model rock materials. It is suggested a standard laboratory rock cutting test by international rock mechanic commission (ISRM) [15] to measure the cuttability of rocks. Specific energy is defined as the amount of energy required to cut a unit volume of rock. Specific energy value is the most popular method in order to predict the efficiency of cutting machines. In this test a cubic of 7 cm. in length is fixed in a table of a shaping machine and cut by a chisel pick having a rake angle of 5 degrees, a clearance angle of 5 degrees, tool width of 12.5 cm and a cutting depth of 2 mm. as a standard conditions. The tool forces in three orthogonal directions are recorded using a force dynamometer and the specific energy in MJ/m3 is calculated by dividing the mean cutting force FC by the yield Q (the volume of
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rock or mineral obtained by unit distance of cut). The test results, which may be classified as index values, are evaluated according to previously accumulated field performance data. As shown in Fig. 2 linear cutting test set.
Fig. 2 Linear cutting test set

5 Development of Cutting Theory for Rock

In cutting theory, firstly, the relations between the cuttability and some mechanical properties of model rock samples have been evaluated. Later, the meanings of these relations have been evaluated as statistical. As meaningful, resulting (in the light of this study, and the data obtained from digger) is derived from a theory of rock cutting use of relationships. The biggest difference from the other cutting of the theory is that is made by creating a model of rock samples. The biggest advantage of this kind of rock samples be homogeneous, hence many physico-mechanical property of the fixed order of rock has been. In this way, the rocks cuttability, the evaluation of the parameters affecting the hardness and resistance has been more easy and correct. The resulting equations are given below the graphics and showing the relationships created (Figs. 3 and 4). As you can see from the Figs. 3 and 4 between specific energy and uniaxial compressive strength, Schmidt hardness meaningful relationships has been achieved. This is obtained from the relations in the light of the theory of multiple regression were applied in order to develop a mathematical model. Cutting

prediction model for rock (cutting theory) is presented in equation 1 which was obtained by multiple regressions.
276 N. Bilim and B. Keke Fig. 3 Relation between Schmidt hardness and specific cutting energy Fig. 4 Relation between Uniaxial compressive strength hardness and specific cutting energy

SE=32.45+0.59UCS-0.71SH SE: Specifik energy (MJ/m3) UCS: Uniaxial Compressive Strength SH: Schmidt Hardness
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6 Conclusions
Homogeneous model samples have been prepared in this study and have been researched the influence of rock properties in conclusion of cutting tests. it has been determined that the most effective parameter in rock cuttability is hardness and strength. The aim of this study is to estimate the most correct rock cuttability, so an estimation model has been developed. The rock cuttability has been estimated easily with this model.