Failure Probability of Thermally Stable Diamond Composite Tips for Cutting Rock Segments

Thermally Stable Diamond Composite (TSDC) tips have attracted a great attention of rock cutting industry due to the higher thermal stability and high wear resistance of TSDC. To make the TSDC tipped picks practical for real application, it is important to understand the failure behavior of the TSDC tips for rock cutting. One of the failure characters of TSDC tips is random failures. In this paper, a method is proposed to calculate the failure probability of TSDC tips for cutting individual rock segments. This method enables to link the segment length to the failure probability of the tip for cutting the segment. A numerical case study is presented to validate the method. The method can effectively reduce the impact of the number of segments on failure probability estimation accuracy.

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A Simplified Approach to the Failure Probability Assessment of Thermally Stable Diamond Composite Rock Cutting Tips

Materials Science Forum ◽

10.4028/www.scientific.net/msf.976.62 ◽

2020 ◽

Vol 976 ◽

pp. 62-68

Author(s):

Yong Sun ◽

Xing Sheng Li ◽

Hua Guo

Keyword(s):

Failure Probability ◽

Rock Cutting ◽

High Wear Resistance ◽

Failure Behavior ◽

Thermally Stable ◽

Diamond Composite ◽

Simplified Approach ◽

Cutting Length ◽

Numerical Case Study

Thermally Stable Diamond Composite (TSDC) has high thermal stability and high wear resistance, and hence is potential to be used as cutting tips for hard rock cutting. Understanding the failure behavior of the TSDC tips during practical rock cutting is a key to enable the TSDC cutting tips to be applied successfully in mining and construction industries. Previous research has shown that the character of random failures due to excessive bending force on TSDC tips is of a major concern, and an approach to estimation of the failure probability of TSDC tips for cutting a rock segment has been developed. However, this approach requires the acquisition of the total cutting length of rock by a tip since it is brand new to it is failed, which can limit the application of the approach. In this paper, a simplified approach is proposed and compared with the existing approach through a numerical case study.

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Influence of Roof Rock Thickness on the Failure Probability of Thermally Stable Diamond Composite Rock Cutting Tips

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.878.98 ◽

2021 ◽

Vol 878 ◽

pp. 98-103

Author(s):

Yong Sun ◽

Xing Sheng Li ◽

Hua Guo

Keyword(s):

Failure Probability ◽

Failure Modes ◽

Roof Rock ◽

Cutting Temperature ◽

Rock Cutting ◽

Estimation Accuracy ◽

Thermally Stable ◽

Diamond Composite ◽

Sudden Failure ◽

Underground Coal Mines

Thermally Stable Diamond Composite (TSDC) has been used to make rock cutting tips to tackle the challenges of high cutting temperature and high abrasiveness met in hard rock cutting. Various research has been conducted to investigate the failure behaviour and predict the failure risk of the TSDC tips in real rock cutting operations. Based on the scenario of roadway development in underground coal mines, a series studies have been carried out to estimate the probability of TSDC tip sudden failure suffered from randomly occurring excessive bending force, which is one of major failure modes of the TSDC tips. This study aims to improve estimation accuracy of the failure probability by removing the constraint on roof rock thickness that has been adopted in existing research.

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Failure Probability Prediction of Thermally Stable Diamond Composite Tipped Picks in the Cutting Cycle of Underground Roadway Development

Applied Sciences ◽

10.3390/app9163294 ◽

2019 ◽

Vol 9 (16) ◽

pp. 3294 ◽

Cited By ~ 1

Author(s):

Yong Sun ◽

Xingsheng Li ◽

Hua Guo

Keyword(s):

Failure Mode ◽

Failure Probability ◽

Probabilistic Approach ◽

Rock Cutting ◽

Current Approach ◽

Thermally Stable ◽

Diamond Composite ◽

Extended Approach ◽

Probability Prediction ◽

Improved Accuracy

The Thermally Stable Diamond Composite (TSDC) tipped pick has been developed to replace Tungsten Carbide (WC) tipped picks for hard rock cutting. Due to the material properties of TSDC, a major failure mode of TSDC tipped picks during rock cutting is random failures caused by excessive bending force acting on the cutting tips. A probabilistic approach has been proposed to estimate the failure probability of picks with this failure mode. However, there are two limitations in existing research: only one drum revolution is considered, and the variation of rock thickness is ignored. This study aims to extend the current approach via removing these limitations, based on the failure probability analysis of picks over a full cutting cycle in the underground coal mining roadway development process. The research results show that both drum advance direction and the variation of rock thickness have significant impacts on pick failure probability. The extended approach can be used to estimate pick failure probability for more realistic scenarios in real applications with improved accuracy. Although the study focused on TSDC tipped picks, the developed approach can also be applied to other types of picks.

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Towards Improving Rock Cutting Tools Using Thermally Stable Diamond Composites

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.76-78.585 ◽

2009 ◽

Vol 76-78 ◽

pp. 585-590 ◽

Cited By ~ 2

Author(s):

Habib Alehossein ◽

Xing S. Li ◽

Jim N. Boland

Keyword(s):

Metal Cutting ◽

Cutting Tools ◽

Rock Cutting ◽

Successful Implementation ◽

Geometrical Shape ◽

Dimension Stone ◽

Thermally Stable ◽

Simple Material ◽

Diamond Composite ◽

Tool Replacement

Industrial application of synthetic diamond ceramics is growing very fast due to their super hardness, superb wear resistance and long-life durability. In rock, concrete and metal cutting, drilling, mining and quarrying and dimension stone industries, cutting tools made of diamond composites or impregnated diamond composite segments are gradually replacing the more commonly used cemented tungsten carbide (WC) tools. Through its SMARTCUT research program, CSIRO in the past 15 years has developed harder and stronger thermally stable diamond composite (TSDC) drag picks to encourage and help manufacturing and mining industries improve their cutting performance by replacing these traditional WC cutting tools with the new revolutionary TSDC tools. This improvement process however is much more complex than a simple material or cutting tool replacement, since the mechanism and configuration of cutting are substantially different in the two cutter head systems and its successful implementation requires a better understanding of the basics of rock cutting. Some of the factors influencing the differences are: cutter wear, fracture toughness, compressive and tensile strength, thermal properties, geometrical shape, spacing, angle of attack, rake angle, sharpness and bluntness characteristics, lacing design and cutter arrangements. Besides, it is most important to understand the relation between the tool or tool force and the fragmentation of the rock, which is the main focus of this paper.

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