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Culture Documents
Inal 006881378 PDF
Inal 006881378 PDF
Master of Science
by
A. INAL
December, 1984
SR.P.T10
CERTIFICATE OF ORIGINALITY
(Signed)
Sign ature•
UNIVERSITY OF N.S.W.
-3 DEC 1985
LIBRARY
ABSTRACT
material and only the softest rock and mineral deposits, their
linear rock cutting rig were also undertaken, as was sane additional
measure of diggability.
ii
ABSTRACT i
CONTENTS ii
LIST OF ILLUSTRATIONS vi
LIST OF TABLES X
ACKNOWLEDGEMENTS xiii
CHAPTER 1 INTRODUCTION 1
EXCAVATOR 5
2.1 Introduction 5
2.5.5 Pre-Cutters 27
Page No.
2.6.2 Turntables 32
2.8 Crawlers 40
2.9 Lubrication 42
at Transfer Points 46
Latrobe Valley 57
Page No.
Page No.
REFERENCES 157
BIBLIOGRAPHY 159
vi
FIGURE NO.
Wheel Excavators 11
Conditions 39
Mines 60
to B.W.E. Zone 70
LIST OF TABLES
Wheel Excavators 67
Block Samples 75
Samples 76
of Artificial Samples 79
LIST OF MAPS
INTRODUCTION
economy with the necessary raw materials and these must continue
maintained.
orebodies.
oil sand deposits, where the nature of the oil sand itself
when the water film around the sand particles causes the mined
oil sands to freeze into solid lumps. The oil sands themselves
undue wear and tear. For this the designer needs to know the
These results have been compared with those obtained using the
wedge test apparatus and correlations made between two sets of data.
5.
CHAPTER 2
2.1 Introduction
the need for the development of land operated, bucket chain excavators.
In 1827 and again in 1859, bucket chain dredgers very similar to their
The oldest European patent, (Germany, 1906) was granted to S.J. Loyd
and A.R. Grossmith (2) . This patent provided for a cutting wheel to be
field put into service the first rail mounted bucket wheel excavator for
cheaper mining methods and began using bucket wheel excavators which were
put into operation at the Cuba Mine, Illinois, of the United Electric Coal
11
V"
ii iiii !■
-V
6.
FIGURE 2.1 Details of an 1881 Patent for a B.W.E. (After Rasper).
7
FIGURE 2.2 First Rail Mounted Bucket Wheel Excavator.
8.
FIGURE 2.3 Bucket Wheel Excavator at The Cuba Mine, Illinois (After Kolbe) .
9.
Wellman Engineering Co. was put into service for overbuden removal in the
lignite opencast mine of the Truax Traer Coal Co. in North Dakota (2) ,
as shown in Figure 2.4. At the same time, in the U.S.S.R., East Germany and
today has a range of machines 0 to 5 designated, which are built for small
to medium digging height ranges. The smallest machine has two crawler
tracks, and the largest which is already in service has up to eight crawler
tracks.
2.5.
Each of these methods can make use of terrace cuts, dropping cuts, or
N
1.0
FIGURE 2.4 The Bucket Wheel Excavator Sch Rs ~ --- 25 (After Rasper).
.
11.
When undertaking terrace cuts the buckets on the front side of the
wheel do the cutting, while in the dropping cut the buckets on the under
of equal height, with between 40 and 70 per cent of the wheel diameter being
height to diameter and the nature of the material excavated. At the start
of the top terrace the wheel is in the retracted position, and at the end
finished the thickness of the next slice is set by moving the excavator
The dropping cut is often employed where the nature of the deposit
to clear the face, see Figure 2.7c and 2.7d. The wheel is then set at
and retracting the wheel to give the batter angle. Slewing to 90° is
13.
thrust retracted
THRUST extended
thrum ^CNOt°
FIGURE 2.8 Block Working System of Bucket Wheel Excavator (After Scott).
FIGURE 2.9 Face Working, Rail Mounted Bucket Wheel Excavator (After Rasper) .
16.
common, so that the front and slide batter have the same slope. In the
dropping cut the slice thickness remains constant but the segment slope
height gradually decreases to zero at a slew angle of 90°. When the wheel
reaches the bench level a small toe ridge is left between it and the
digging" conditions are more efficient with the dropping cut, because it
controls lump size better and allows the high speed conveyors to operate
method.
and continuously slewing the bucket wheel, while at the same time the
bucket wheel excavator is driven straight along the face length, as shown
in Figure 2.8. The best results are obtained if the block is as wide as
of all sizes.
In the face working method the excavator travels along the working
face.
17.
Face working can only be applied in good conditions where the bench
slope angle gives good slope stability. Figure 2.9 shows a rail mounted
Face block or side block working is the method most camionly adopted
in the U.S.A. black coal mines, where a bucket wheel excavator operates
The bucket wheel excavator removes the top layers and overcasts
wheel excavator travels on top of the coal seam and often has a boon crowd
action because of the need to reach over the lower overburden layers.
In addition, the discharge boon must be long enough to clear the shovel
spoil.
than for the full block method but much shorter than for front face working.
Face block operations are generally used for the selective mining of
tasks which they have to perform. However, they are substantially influenced
STRIPPING
SHOVEL
WHEEL
EXC.
47'-50'
can be loaded into trucks, onto trains or directly onto shiftable face
conveyor belts which usually stack directly onto spoil piles. Finally,
machines.
have been developed and tested, in which improvements to the wheel design
of the soils, the strength of the soil, and the output volume to be
common wheel configurations are the cell, cell-less and semi-cell types.
20.
With the cell type wheel, as shown in Figure 2.11, the wheel
The individual cell walls are joined to the cone shell of the wheel body
where they are rounded. The cell contours are mostly arranged at a tangent
cell there are two vertical chutes down which the material is tipped and
which prevents a lateral emptying of the material during the cutting and
filling processes.
A cell type wheel requires a longer wheel boom for deep excavation
but gives the best results, especially when operating in coarse and lumpy
of each bucket into the wheel body, as shown in Figure 2.12, and this
the very short distance covered by material in the buckets before it leaves
the rotating ring space, and the almost free discharge. Thus a higher
Fi
... ['■//•
Slope Sheet
FIGURE 2.13 Bucket Wheel Discharge Types (After Drust, Rasper, Rodgers).
23.
FIGURE 2 .14
2.14 Bucket Wheel Discharge ~jpes
Types Photos (After Rasper)
Rasper).•
24.
i.e. grain size and shape, water content, adhesion and cohesion; the wheel
speed; wheel design; i.e. wheel diameter, chute angle, bucket shape; and
canted wheel and a belt feeder, as illustrated in Figures 2.13 and 2.14.
The semi-cell type wheel is a compromise between the cell type and
pressure of material on the ring chute and also the wear on the ring chute.
Compared to the other two forms of the wheel design, the semi-cell
wheel has the highest degree bucket fill (Figure 2.16) , with the best
remained in the bucket after passing its highest position to drop down
Bucket edge plates are usually formed on-site using a cutting torch.
In very abrasive soils, good results can be obtained using the following
materials to reduce wear; line tax, a soft kind of rubber, plastic material
and teflon.
For sticky soils, the chain-back type bucket is now in general use.
The chain mats hanging freely in the cut-out back of the buckets are pulled
inwards by gravity and thus help to discharge the material which tends to
2.5.5 Pre-Cutters
similar to buckets but are without backs and are spaced between the buckets.
The pre-cutters improve the running of the wheel, especially when the
bucket operates in a full cutting mode when using the dropping cut method.
With these advanatages, the requirement for a larger wheel is not considered
as that of buckets.
The bucket teeth are useful in every type of soil, except for loose
sand. They break up the cutting face material with their wedge action and
thus decrease the wear on the bucket knives. It is important that teeth
BUCKET/vO
INTER
8W RADII
HORIZONTAL „0*
INTER CUT TER
BUCKET
VIEW 'A'
for excavating in hard soils; cutting geometry; long life, rigid mounting,
of the tooth material and the properties of soil being excavated. The
bucket teeth cutting edges are generally protected against wear by means
carbide inserts).
bucket teeth.
The position and shape of the teeth must be chosen to take into
account the cutting process, e.g. specially designed strong cornered teeth,
at least two side teeth and centre teeth for starting the cut, as shown
in Figure 2.21.
In full block operation, the slewing mechanism provides the necessary motion
BUCKET
Comer Teeth
gear for rotating the superstructure and the turntable for transmitting
the loads.
The slewing drives are needed not only to slew the superstructure
overload brakes) . The slewing gear motor must be rated so that the
For giant and medium size machines only, load independent, infinitely
The American bucket wheel excavators use a roller race mounted in the
to the portal. The German bucket wheel excavators use a ball race, which
vertical and horizontal loads, thus eliminating the need for guides.
2.6.2 Turntables
The largest examples of this type are probably the two concentricaly
2100
FIGURE 2.22 Turntable on the BWE Sch Rs 35 11
4
(After Rasper)
As ball races are able to transmit both vertical and horizontal loads,
no guides are necessary for the transmission of lateral loads. The entire
inner portion of the race is available for the conveying system and the
material flow stream can be conducted through this area. At the same time,
slip rings for power and control circuits can be accommodated, see Figure
2.24.
smaller counterweights and crawler loads. This trend is shown in Table 2.1.
Crawlers 1 763 mt
Chassis 1 601 mt
Turntable 293 mt
Superstructure 1 296 mt
Wheel Boom 992 mt
Total Construction Weight 5945 mt
4500
TABLE 2.1 Steel Structure Weight for BVtfE Sch Rs
12
(After Rasper)
37.
three supporting points with six constraints, with not more than three
constraints passing through one point of intersection and not more than
which carries the main slewing mechanism and is supported by two or three
crawler groups and a revolving upper platform with supporting frames for
the bucket wheel and discharge boons. The bucket wheel bocm and dumping
The most practical and frequently used design for the substructure
framework consists of two rigid space trusses, i.e. the bucket wheel boon
and counterweight boon. Small to medium excavators are often built with
C-frame design for the upper structure, while for giant excavators a
for the excavator should remain within the ball race core circle diameter
unbalanced situations.
38.
2.8 Crawlers
excavators are shown in Figure 2.27. All these designs may be categorised
in five groups, ranging frem two crawler units to twelve crawler track
method.
All crawler units (except the two crawler type) are steered through spindles
with the crawler being controlled by one or even two spindles. Sometimes
The travel drives are reversible so that the excavator can be moved
4
HHii jifh-1
safely transferring the load to the ground, with not only vertical loads
time period as the excavator has to travel only short distances. Special
care has to be taken, therefore, that all gear elements are well lubricated.
2.9 Lubrication
with about 3000 lubricating points, yet should require only one mechanic.
resistance to ageing. Also, both oils and greases are of such a chemical
substructure and lubricates the mechanical parts of the travel gear and
the main roller bearing slewing rim of the supersturcture. The other
system is arranged on the excavator turntable and supplies the upper hinges
of the excavator.
43.
P=250mt(f)
| A = 1980 cm2
p=250000/1980~125 kg(f)/cm2
oil level
drain cock
P= 2000mt(f),
A = 10 £00cm2
p = 2000000/10£00
= 190 kg {11/cm2
gauge cock
gauge cock
lubricated surface
For the bucket wheel gear boxes, and also for the gear boxes of belt
conveyors and hoisting winches, force feed lubrication is used. For many
lubrication is used. The ball cap can be filled with stand-oil which will
If the ball centre is below the edge of the spherical cap, pressurised
with the assanbly groups. They are set to transmit air pressure generated
pumps.
must be used to take material away frcm the bucket wheel excavator;
belt). When one belt fails, the drives of the previous belts must
45.
FIXED CONVEYOR
I SHIFTABLE CONV,
DECK SECTION
shifting rail
.timber tie
Details of Shiftable
IlfCTT. -.—7 I «---- ggg
Conveyor
In order to minimise the number of conveyor shifts for the main bench
with a special arm and head attachment. The distance between the centre
of the excavator and the bench conveyor must be bridged with either a short
crawler unit.
transfer the material frcm one belt to another on the same axis, but at
that the flow of material drops verticaly in free fall onto the next
Schn. C-0
FIGURE 22.31
.. 31 Possible Transfer Point Configurations
(After Scharf)
Scharf)..
48.
influence of the wear on rubber strips, small rubber belts can be made to
number of belts on one unit has been reduced, thereby eliminating transfer
points and short belts. Modem units have only four conveyors from the
bucket wheel to the loading point; bucket wheel bocm belt, a centre belt
loading to the bridge, extendable bridge belt, and the loading belt.
direction of the belt taking the material away. This is due to the belt
The present day trend in designing the conveyor path of bucket wheel
gratings, see Figure 2.32. This development has been made possible by
Belt 1 Belt 3
are made complete with sides, as an aid to straight running, and can only
with conveyors, provided that production is not too large and the haul
A strong trend has developed in Germany away from rail transport and
towards conveyors.
rail tracks with the ccmbination of a slewing belt with two adjacent loading
52.
Seme advantages of rail transport which offset its high initial cost
The size and rating of excavator drive motors depends upon the load
does not physically operate each, as remote control and automatic sequences
The incoming supply for all giant bucket wheel excavators is at high
The start-up process is then initiated frcm the discharge end, the
the machine. Warning systems, such as wind warning for large machines,
buzzers, bells, sirens, and light switches are also located throughout
the excavator.
56.
^
1
FIGURE 2.37 BWE Cable Reel Car (After Rasper & Joachim)
57.
CHAPTER 3
AUSTRALIAN EXPERIENCE
one hundred and fifty kilometers east of Melbourne. The extent of these
to the Yalloum and Morwell coal fields, however, development of the Loy
and plans for future power generation are also based on the utilization
The development of equipment for the SECV open cut mines, as shown
in Figure 3.2 has been carried out in several ways. Older machines have
been modified and now ones designed from experience gained in operation
of clayey silts and silty sands and is regarded as very sticky and
difficult to handle. For this reason the buckets and wheel ring space
are lined with linatex, a soft rubber which prevents clogging of the
ROCkhauPTon
Cl_AOSTO*£
a; co
3 s^own zo*l
*sr Tgk4*~Bh \
nEWBOROUGH *g^00ff&i$b ? *Z.innS Vat Latrobe River f
^YALLOURN .*ri Railway
g<VpHERNESJfc^Yalloum-Maryvaie field Sheepwash
d/fys r^iwi A \\'i.\'\ Creek
Jg%=K fffitMkmmJ '&&rZ/7sV/A^ ) L0YYANQ
^^^l^fYALLOURN OPEN CUTX^7//M ^e8 IELD
AmHBH I }J////A Highway^^*^ Xs////s///A 'A ‘ r-^
Anderson' s Creek/W/V/VA S/^X ,.<::::£ ( ^SA'-'' m) Flynn s Cfeek
IS^fe^iiL/
t'r****
a/ Morwell
1/0Mr<^C
/T
f \
h open cutjjf/ loy yang
H!iliHH::H!ll|i«4llfr( POWER STATIONS
>
/
v\ river diversion \7 LEGEND I x / ^
W \ / ^MORWELL
\\ ' \j ^OPEN CUT Cities 4 townships £2 {&::{»..*<§&»•
N^V ! V Boundary ot main ___ L 1=3 ;It.
MORWELL< )r\AA coal reserves S i{jjO^^urdenits
NARRACAN1 \ Areas of coal PTH \ ,':::::::p;j dump
FIELD ^YV reserves investigated1^ Traralgon
Hazelwood/Zt Existing power station □ ^ Creek
^ cooling Existing open cuts m|
Morwell , P000* v\//////77////////A ___ Kilometers
River ^^\J^///////////J P^ned open cut [—-|
r-r~A v/ffi////'//////f extensions ?! 2 3 4 5
Z/?yinnar ^/^churchill //^
Plan ol the existing open cut mines and the Loy Yang protect in the Latrobe Valley
COAL TO SEAM
RESOURCES OVERBURDEN THICKNE
COALFIELD (million metric tons; RATIO (metre:
Anglesea 400 160 1:1 30
Bacchus March 100 20 1.5:1 25
Gelliondale 1,000 200 3:1 50
Gormandale 2,400 600 1:1 200
Holey-Plains-
Coolungoolun 250
Loy Yang 12,500 4,700 4:1 250
Morwell 6,700 3,300 4:1 100
Rosedale 1,400
Stradbroke 500
Yalloum 9,500 2,800 3.5:1 60
I 'd·l\~
~',
'f0
',
·~em
fi1
~4m
I
U2_Q_
I
<~~·9m
BUCYRUS
1508 SHOVEL
BUCYRUS BUCKAU R. WOLf ES ~~~ 8·8 RUSTON - BUCYRUS BUCYRUS
175B SHOVEL 100RB SHOVEL
DIPPER 1·9 ml Dl PPER 2·7 ml 120B SHOVEL
N°· 208 DREDGER DIPPER 2·7ml
1922 - 1926 &. 1928 DIPPER 3·8"'1
1923 - 1933 1928 - 1953 1942 - 1944 1942- 1945
1940 - 1942
1947- 1953
tom. o 10 20 30 40 som.
I I l II I I II ,I I I I I I I I I I I
60
0'\
.
0
\] 0
~\!
.<.R ~
..:PP
- -
No 59 - DS 650 ~~, ~-
-~ KRUPP N°· 93 SchRs 1
~.~0 19·8- 9 KRUPP N°· 1320 SchRs 1
~?g 23
12-15 .
' S :._ · v No 4DREDGER) :.Q_~m (S LCV N° 7 DREDGER) ( S.E.C.V. N° 13 DREDGER)
1951 - 1963 1958 - 1976 1977-
FIGURE 3. 2 Developrent of Equipnent for Victorian Open CUt Mines (After Rodgers) .
61.
mixed and impregnated with humic substances. Brown coal hardens and its
strength increases with depth within each seam. Because of that the
gearing of the bucket wheels can be changed so that the wheel can turn at
two different speeds. The low speed is for operations in the overburden
and the higher speed for mining the coal. The design also allows for
in Figure 3.3.
and follows the progress of the machine above it. The bucket wheel
seams ranging from six to ten metres in thickness. The mine strike length
is about eighteen kilometers with the seams dipping at about five degrees.
mine has already reached the stage where draglines alone cannot operate
62.
/ LINATEX LINING
ING SPACE /
capacity L return back of bucket
without very expensive rehandling of material and the mine could not
pre-stripping equipment.
meet seme of the most arduous conditions yet encountered by this type
obtained for Goonyella and in this case for drawing up the specification
I BASIN
newlan\s® '
lance wodo e x.
WAR03 ) CREE'
WELL k O e'DEE CREEK
\ KEMMS V
GOONYELLA tJAWALKERWSCyjH WALKER|
vUy-err
POITREl\ 9® DAUnU x \
BASIN
^ B'AS‘N ^
BLAIR ATHOL
V WJRWICH PARK
V ' e GERMAN CREEK
iSXKY CREEK 9 \\
j --Ol. af$EGORYV_^
CAPELUA WEST [ S'YARRABEE
-^^'^Yb^ckw^r nli^iCH^Seor— J \
J I souTH-J^siRius'l^et^ /GLADSTONt^X^
^ y k,an°\T/
Kilometres
MAP 3.2 Goonyella Mine in Central FIGURE 3.5 Detailed Plan of Goonyella
Queensland (After Boyd). Open-Cut (After Maher).
However, the dragline system will remain the main stripping method
for the time being and hence the new system will have to integrate
being used at Goonyella. The bucket wheel excavator has been installed
at the northern end of the mine (Figure 3.5) and overburden has been
pre-stripped to within forty five metres of the top of the middle coal
seam and conveyed to the existing dragline spoil area for stacking.
exposed surface.
66.
the design of the wheel and its drive, to ensure it will be able to
of output, high reliability and without undue wear and tear. To enable
this design to proceed the most important input parameter is the digging
the drive power and geometry of the wheel is based on those test
deposit and other sites where bucket wheel excavators have been
was chosen for Goonyella. Table 3.2 shows the comparison between the
0 & K 1367 and other heavy duty bucket wheel excavators. A general
TABLE 3.2 Canparison Between Three Heavy Duty Bucket Wheel Excavators
(After Rodgers).
CHAPTER 4
could be developed.
be presented in Chapter 6.
The main thrust of all this work has, however, been directed
content.
FIGURE 4.1
I-'
-8 // / \
Ii \ \ ''--/ J I
\\
t-0 / i I1 I '
I-' /I \ \ \ J
/. , . i ; I ', ' '--'
~
en //
I I ' I d ", c
I I I ! ., I
~ ""'>..____,_ \ \
~
lQ
5" ,' 11 / '\ I / .'. / /
.' ~""" \ '-.., '-, ---.__ \ \ ,__).
b
() \ 1I 1 I "-' ./ I j /1// / \\ --- ----- ---- ----- \ \'
. '> - ~ ) \ ' ...__
~ ----J
70
1-'· \ 0
8 \\ \ 1 1 / .21026 """ \ 21s37c-- - - _,
.
0
Hl
l \ ""' \ ,/
\ I / / - ------ - 256 - --
~
/II I I1 1 \ \ / / /
- - ------~
~0 / --- --- 258 -
}D -' ) ~,/ \1 ( ( ' ·"'- ' . \ ""' / / \... / I '--. " '--.. <259
• 21842' "'' - / / - // / ---- '·
Ul
~-
'\ \ ' / _ _____, ' / (•06 ) '
f&
1--' --------.. ,____
/"""'~ "~/ - - ' . / ,21177 260 - ' "
PJ
-~J~ ~
rt ~' • 21324 \ ! -~ '-- \ / / • 21-331'
1-'·
260-~ --
~
8" "\' ,~ r". __ \I -- ,\ \ / ,,. ,
ttl
. 1\ I ' \ '---- 1
.:8 ti:J
. \~ ' /\ l
N
"~_)) ' -~
'" I
.->; tl
1/ ( ( _ (
kept wrapped for the majority of the time with specimens for
cases, left to cure for eight days. On the eighth day all tests
when delivered.
72.
Mix No. Sand (£t) Cement (£t) Water (lt) Lime (£t)
1 16 32 11 -
2 24 24 11 -
3 32 16 8 -
4 16 16 8 16
5 24 12 8 12
6 28 7 8 14
7 21 6 8 21
core and block form. In all thirteen lengths of core and five
and came from seven holes drilled in the area stripped by the
One was fragmented during transport but the other four have been
cored and also used for laboratory cutting tests. Details of the four
cure for eight days all tests were undertaken within few hours.
74.
The results of all compressive tests are given in Tables 4.4 and 4.5.
75.
____________
76.
f
Mix Specimen Specimen Dimensions | Failure Compressive
No. No. Load (KN) Strength
Length Diameter
MPa
1 1 140 55 56 23.58
2 139 55 55 23.16
3 139 55 76 32.00
4 138.5 55 78 32.80
5 139 55 69 29.00
6 139.7 55 68 28.63
7 139 55 63.5 26.74
8 139 55 60 25.24
9 139 55 75 31.58
10 139.5 55 61.7 25.98
Mean 66.2 27.87
4 1 139 55 48 20.21
2 139.2 55 53.6 22.57
3 140 55 49.3 20.76
4 140 55 46.2 19.45
5 138.5 55 50.3 21.18
6 139.3 55 46.2 19.45
7 139.7 55 55.2 23.24
8 139.3 55 46.7 19.66
9 139 55 48.1 20.25
10 140 55 40 16.84
Mean 48.36 20.36 ,
—/
______________l
77
Table .5 Cont'd.
and 4.7.
Specimen Dimensions
Block Specimen Failure Tensile
No. No. Load Strength
Thickness Diameter
KN MPa
mm mm
1 1 28 55 7.3 3.01
2 30 55 7.35 2.80
3 32 55 8.8 3.18
4 33 55 9.8 3.44
5 32.5 55 8.8 3.15
i
6 33.5 55 8.5 2.94
7 30.5 55 7.35 2.79
8 30.5 55 6.3 2.39
| 9 31.5 55 8.4 3.08
10 33 55 9.2 3.23
Mean 8.18 3.00
1 .
2 1 31.2 55 7.2 2.67
2 34 55 6.8 2.31
3 32 55 6.4 2.31
4 33 55 6.8 2.38
5 29.5 55 5 1.90
6 32 55 5.8 2.09
7 34 55 5.8 1.97
8 34.5 55 7 2.34
9 34 55 5.8 1.97
10 33 55 6.8 2.23
Mean 6.41 2.23
r"
3 1 29 55 5.2 2.07
2 29.5 55 5.4 2.12
i 3 34 55 6.8 2.30
4 31 55 5.3 1.98
5 36 55 5.2 1.67
6 30 55 5.5 2.12
7 33 55 6.5 2.28
8 39.2 55 7 2.07
9 33.5 55 6.6 2.28
10 32.5 55 5.6 1.99
Mean 5.91 2.08
5 1 33 55 5.3 1.86
2 30.5 55 4.6 1.75
3 33.1 55 5.5 1.92
4 32.5 55 4.65 1.67
5 29.3 55 4.4 1.74
6 29.2 55 4.1 1.63
7 34 55 5.1 1.70
8 31 55 4.7 1.75
9 31.7 55 4.9 1.79
10 32.5 55 4.95 1.76
Mean 4.82 1.757
The bulk density of the four rock types and the artificial
1 1 32 55 151.3 1.99
2 30.5 55 144.1 1.99
3 30.5 55 144 1.99
Mean 1.99
2 1 34 55 : 160.3 1.98
2 34 55 ! 157.8 1.95
3 34.8 55 166.1 2.01
Mean 1.98
not be used, however, since the clay content was such that the
and 4.12.
.84.
Cl 21177 12.30-12.48
_1
C2 21178 14.32-14.48
_1
C3 21178 19.90-20.05
C6 21324 16.25-16.42 -1
_1
C7 21325 13.06-13.23
1
- Too soft for shore hardness test.
86.
Bl Bl/10 26.3
Bl/11 25.3
Bl/12 26.7
Mean 26.1
B2 B2/10 36.6
B2/11 35.1
B2/12 39.5
Mean 37.1
B4 B4/13 33.4
B4/14 33.1
B4/15 35.4
Mean 33.7
1 1 68.7
2 67.8
Mean 68.2
2 1 63.3
2 67.3
Mean 65.3
3 1 58.4
2 60.2
Mean 59.3
4 1 54.4
2 54.1
Mean 54.2
5 . 1 49.1 ^
2 49.6
Mean 49.3
6 1 36.6
2 39.0
Mean 37.8
7 1 28.4
2 28.8
Mean 28.6
87.
(Figure 4.3).
Cl (21177) 12.30-12.48 - -
_1
_1
C2 (21178) 14.32-14.48 - -
_1
C3 (21178) 19.9 -20.05 - -
_1
C4 (21175) 7.02- 8.16 - -
_1
C13 (21838) 15.8-16.09 —
1 25 36.16 0.69
2 25 37 0.67
3 25 37.8 0.66
4 25 39.2 0.64
5 25 52.4 0.48
6 25 58.7 0.43
7 25 59 0.42
91.
CHAPTER 5
or cutting circle.
Qeff X*
Ndig _ iQ2 [kW]
f = swell
93.
n = reciprocal of 1 + t /t
S cl
3
Qth = theoretical output (= 60 js) [m /h loose
material]
bucket [m^]
k Qth S nf
dig, Min
0.00584 % R [kW]
nf bucketfill %
f amount of swell
power and hourly output is not linear, but a parabolic function (2).
94.
kg(f) /cm.
expressed as kg(f)/on2,
and
fAL = tkg(f)/an3]
gauge.
in Figure 5.1.
96..
the force exerted on the test sample by a hydraulic ram and wedge.
and bending of 140 MPa, the factor of safety for the apparatus
Load _ 12.5x4
Stress in each rod
Area TT 19 -
= 44.1 N/nm^
= 44.1 MPa
140
Factor of Safety 3.17
44.1
base
then
16250 + 220350
236600
y 45.5 mm
5200
o 13 X 50J l.io
=
2\—tt:---- > + 13 x 50 x 20. 52
+
300 x 13-
+ 300 x 13 x 11
2
1343 983 mm
= 84.6 MPa
The final aspect of the design was to check that the rods
would not pull through the base plate. The cross-flat distance
= tt x 36 x 13
= 1470 rnn2
Load = 12.5 kN
© 0
ff 1
—1—1—f—
Vi/
-4>-
UNSW
DRAWN A. INAL
c_
1
®
part name
SCALE
'.OB »
BOTTOM PLATE
DIMENSIONS
WEDGE TEST
MACHINE
UNSW A. INAL
.·' . . . .
• I
: '1 '
~
~,· ~ \ ..
:.. • -~ .d
...,. ~·;,_ J~
·. -.~
.............. , ;,..___ ~ _:.;a._---~
.:~
equal to the diameter, the cores were placed in the sand tray
The stronger mixes proved too hard for testing using the wedge,
bucket wheels were tested using the wedge apparatus, in the same
After initial contact between the wedge and the top of the
over which the specimen failed was obtained by tracing the shape
Results of the wedge tests are given in Tables- 5.1, 5-2:and 5.3^
106
Specimen Dimensions
Specimen Failure Failed Rock
No. Load Area Strength
Length Diameter
kN cm2 N/an2
mm mm
C3 - - • -
_ *
**
C8 110 140 13.3 167 77.84
C9 150 140 31.7 140 226.1 ~
CIO 150 140 6.5 224 29.0
Cll 145 142 19.0 208 91.3
Cl 2 150 140 1.5 127 27.6
Cl 3 130 140 14.0 189 74.0
/
Table 5.3 cont
shapes. Large diameter (150 mm) holes are expensive to drill and
sites where the overburden is exposed and where wedge tests are
specimens.
was used for this work and the mixes chosen were number 5,
i.e. the yellow and pink sandstones were also weak enough to
the Avery test machine. The results obtained fran tests using
Figure 5.13.
Table 5.4 Effect of Specimen Size on Wedge Test Results
Area of
Specimen Dimensions Load at Material
Sample Failure
Failure Strength
No. Diameter Length Plane
mm mm kN (cm2) N/cm2
1 50.05 51.5 6.97 27.45 253.91
2 50.05 49.5 6.82 24.72 275.89
M 3 50.06 52.5 7.26 26.8 270.89
4 50.05 51 7.40 27.03 271.06
I 5 75.07 76.5 13.64 60.26 226.35
6 75.05 76.22 11.15 51.83 215.13
X 7 75.08 77.2 14.92 60.26 247.59
8 75.07 76.5 13.24 58.96 224.56
5 9 103.2 101.5 23.11 107.28 214.28
10 103.5 103 24.79 118.27 209.6
11 103.3 102.6 16.55 94.66 174.84
12 103.3 102.5 24.39 105.1 232.06
13 124.6 125.5 29.03 161.26 180.02
14 124.8 127 30.19 162.4 185.9
15 124.5 127.2 30.48 162.96 187.04
16 123.8 128 25.84 161.14 160.36
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DIAMETER OF CYLINDRICAL SAMPLES (mm)
FIGURE 55.13
.13 Carparison
Comparison of CUbic
Cubic and Cylindrical Specimens after Testing.
121.
varying size. Figures 5.10, 5.11 and 5.12 show that the same effect
12.05, 6.85 and 4.81 MPa respectively (Table 4.5) and, in general,
the wedge tests results reflect these differences, with the highest
values being observed for Mix 5 and the lowest for Mix 7. Taking
Table 5.5) were in the ratio 1.8:1.04:1 for the three mixes.
prism and the second group comprised cubes with 150 mm sides and
diagonal dimensions of 212 mm. Table 5.5 and Figures 5.10, 5.11
and 5.12 show that the wedge test strengths of cubes were lower
in Chapter 7.
122.
CHAPTER 6
and B4) using 250 mm cube specimens sawn from the original
block. The single pick linear cutting rig used was a modified
which was:
Power 5.36 kw
pick holders, could accept any normal size and shape of cutter
FIGURE 6
FimRE .1
6.1 Linear Rock Cutting Rig and Pick Dynarnaneter.
Dynamometer
124.
After each cut had been completed the rock debris was
equipped with twenty four strain gauges (120 ohm foil gauges,
the dynamometer used for these tests was machined from a solid
when cutting.
process the data and provide hard copy of relevant force values,
The results for the block sample (B2), yellow sandstone (B3)
and pink sandstone (B4) are given in Tables 6.1, 6.2 and 6.3
and presented graphically in Figures 6.4, 6.5 and 6.6. The results
obtained conform with those found by other research workers (6) (7) (8) .
128.
A) Forces
PEAK
7-
(K N )
8-
C U T T IN G F O R C E S
5-
4-
MEAN
3-
2-
1-
i---------------------------1-------------------------- ------ r-
5 10 15
DEPTH OF CUT (mm)
co
UJ 3-1
o
QC
o 2- PEAK
u.
z
_J ¥ MEAN
< 1 -
DC
o
z T I
5 1 0 1 5
DEPTH OF CUT (mm)
1.1- -650
1.0- -600
0.9- - 550
C O A R S N E 3 S INDEX
0.8- - 500
0.7_ - 450
0.6- - 400
0.5- - 350
0.4- -300
0.3- -250
0.2- - 200
1 4-
SPECIFIC ENERGY (MJ/m 3
1 2-
1 0-
8-
6-
4-
2-
i ]-----------------------r-
5 10 15
DEPTH OF CUT (mm)
FIGURE 6.4(B) Effect of Depth of Cut on Yield and Specific Energy in Block B2
132.
5 0.43 0.89
5 0.37 0.84
5 0.41 0.86
5 0.32 0.92
5 0.38 0.84
Mean 0.39 0.87
10 0.67 1.34
10 0.66 1.23 j
10 0.66 1.36
10 0.88 1.61
10 0.80 1.44
10 0.65 1.28
10 0.67 1.33 |
10 0.65 1.33
Mean 0.70 1.36
15 1.42 2.66
15 1.32 2.40
15 1.23 1.96
15 0.97 1.78
15 1.06 1.84
15 1.08 2.02
15 1.15 2.02
15 1.05 1.86
15 1.01 1.84
Mean 1.14 2.04
133.
M EAN C U T T IN G FO R C E
1.2- -7 00
1.1- -650
1.0-
-600
0.9- -550
C O A R S N E S S IN D E X
0.8- - 500
0.7- - 450
0.6- -400
0.5- - 350
0.4- - 300
0.3- - 250
0.2- -200
>
(3
A) Forces
8-
(K N )
7-
C U T T IN G F O R C E S
8-
5-
4-
3-
2-
1 -
------------,------------------ r-
T
5 10 15
DEPTH OF CUT (mm)
-700
1 . 1- -6 50
1.0- -600
0.9- - 550
C O A R S N E S S IN D E X
0.8- - 500
0.7- - 450
0.6-
- 400
0.5- - 350
0.4- - 300
0.3- - 250
0.2- -200
1 2-
( M J /n f
1 0-
S P E C IF IC E N E R G Y
8-
6-
4 -
2-
I I
5 1 0 1 5
DEPTH OF CUT (mm)
in Block B4
140.
6.6 are for the three main types of overburden excavated during
established are similar for each of the rock types, with only
swept by the tool (see Figure 6.7) , yield will depend on how
Yield = Wd + d2 tan 8 . . ( 1)
141.
K— W -X
increases using the values of yield and the face that pick
Table 6-. 4.
142.
B2 5 51
10 63
15 66
B3 5 54
(Yellow Sst)
10 60
15 55
B4 5 65
(Pink Sst)
10 72
15 66
angle varying with depth of cut. The three individual rock types
with B2, B3 and B4 giving values of 60°, 56° and 68° respectively.
and the curves for all three rocks show that specific energy
depth of cut, showing that the average size of product has also
the three block samples used for the cutting tests have been
Test B2 B3 B4
discussed and it has been noted that the trends are similar.
Curves for mean cutting force and specific energy have been
abstracted from Figures 6.4, 6.5 and 6.6 and are presented for
M E A N C U T T IN G F O R C E S (K N )
2
>
O
cc
UJ
z
LU
o
U.
O
UJ
CL
CO
forces and energies in the two rocks. On the other hand the
soft, yellow sandstone B3, with a high clay content and a silty
CHAPTER 7
CONCLUSIONS
cuttability.
The first objective has been met in full. The wedge test
and so only one specimen was wedge tested fran Block 2 and three
specimens frcm both Blocks 3 and 4. Figures 7.1 and 7.2 do,
is known.
ui
t-
60--
MIX 5
5 0-
SHORE HARDNESS
i
40- MIX 6
I
{
Ml|7 5
30- B4
20-
10-
GC 0.5-
Ui MIX 6
H
Z
Ui 0.4- MIX 7
o
z
Ui 0.3—
z
o
O 0.2-
100 200
WEDGE STRENGTH OF ROCK AND
ARTIFICIAL MATERIAL (N/cm2)
size of quartz grains, etc. can all have a large effect and
size of the probe and shows that once penetration of the harder
Hardness in Figures 7.5 and 7.6. These results shew that both
between cutting force and wedge test results will also shew a
es
z
H DEPTH OF CUT
H
3 (mm)
O
*
<
UJ
a.
DEPTH OF CUT
(mm)
CONE INDENTER
m e a n c u t t in g f o r c e d e p t h
/
0.4-
(K N /m m )
0.2-
DEPTH OF CUT
(mm)
way with wedge strength. This would imply that the energy
and rotational speed Truong was able to calculate torque and hence
production rate i.e. material strength was not the only factor
as
f = specific resistance on the basis of power consumption
material strength from, wedge test
with the standard cuttability tests and with recorded machine data
frcm Goonyella, the relationships are not linear. This means that
other factors are also involved in the "diggability index" and that
BIBLIOGRAPHY
Aiken, G.E. "BWEs: How to Choose the Right One for the Job"
pp. 232-243.
pp. 1209-1213.
pp. 139-157.
pp. 1587-1590.
pp. 139-146.
pp. 72-85.
W.F.
pp. 168-174.
Maher, B.J. and "Open Cut Systems for the Eighties". Int. Conf.
163.
163.
p. 36.
Naidu, B.S.D. "New No. 12 Dredger for SEVC goes for "Walk"
May 1974, p. 7.
pp. 37-41.
pp. 289-295.
and Mitchell, D.H. The Engineering Conf., April 1978, pp. 248-256.
pp. 619-629.
Tweedly, B.W. "The Loy Yang Overburden System". The Aus. I.M.M.