Design and Performance Analysis of a Cutting Head for Longitudinal Roadheader

Introduction: The longitudinal roadheader is a critical piece of equipment in coal mining operations. As a key component, the cutting head plays a pivotal role in determining the machine's performance, operational reliability, and service life. Methods: This study aims to design a high-performance cutting head compatible with the EBZ220 roadheader. An auxiliary design and load calculation program was developed based on the design theory of cutting heads and rock fragmentation mechanisms. A patent for a novel cutting head design was proposed, and the load acting on the cutting head was simulated. The load was applied as an external excitation to the established rigid-flexible coupling dynamic model of the roadheader. Results: Simulations yielded dynamic stress distributions for the rotating platform and main frame, along with maximum nodal stress variations. When the roadheader operates at full power and a maximum slewing speed of 1.106 m/min, the maximum stresses on the rotating platform and main frame are 214.24 MPa and 272.30 MPa. The maximum vibration frequencies were identified at 105.7 Hz, 179 Hz, and 211.2 Hz for the rotating platform, and at 103.27 Hz and 108.89 Hz for the main frame. Discussion: The cutting head designed by the auxiliary design and load calculation program can ensure that the maximum stresses on the rotating platform and main frame are both lower than the yield strength of their materials under the condition of maximum slewing speed. The load on the cutting head is not the main cause of the intense vibrations of the rotating platform and the main frame, which verifies the rationality of the structural design of the cutting head. Conclusion: The performance of the cutting head and the reliability of key components were further validated through industrial tests. The novel cutting head design described in the patent enhances the reliability of the roadheader's key components.