Numerical Investigation of Rock-Cutting Mechanics and Energy Efficiency of an Oscillating Disc Cutter

Conventional roadheader cutting tools are subjected to substantial forces, intense impacts, and friction during rock excavation, resulting in excessive energy consumption and accelerated tool wear. To address these challenges, undercutting technology has emerged as a promising alternative for integrating disc cutters into roadheaders. In this study, a comprehensive mechanical investigation is conducted on an Oscillating Disc Cutter (ODC) based on the undercutting principle to enhance fragmentation efficiency and minimize energy requirements. A high-fidelity numerical framework, coupling the Finite Element Method (FEM) and Smoothed Particle Hydrodynamics (SPH), is established to simulate the dynamic ODC cutting process. This model is rigorously validated against both theoretical analyses and experimental data. Results demonstrate that the ODC can reduce the minimum specific energy by 78% compared to conventional non-eccentric cutters and attenuates the average rolling, side, and normal forces by 70.9%, 59.4%, and 67.9%, respectively. Furthermore, parametric analysis reveals a strong sensitivity of cutting performance to oscillation frequency and feed rate. These findings confirm that the ODC mechanism effectively mitigates cutting resistance and optimizes rock fragmentation, providing essential theoretical and practical guidance for the development of high-efficiency underground excavation equipment.