Skip to main content
SpringerLink
Log in

Design of Pin-on-Disk Type Abrasion Testing Machine for Durability Assessment of Rock Cutting Tools

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

The accurate evaluation of rock abrasion is essential for the estimation of cutter costs in rock cutting and drilling operations. In this study, a novel abrasion testing machine was developed for rock cutting tools such as pick cutters. The developed machine employs the pin-on-disk abrasion method of ASTM (American Society for Testing and Materials). The Archimedean spiral function was selected as the moving path for the pin on the rock surface. An approximation solution was adopted for the modeling of the inward and outward spiral motions under the constant velocity of the pin. After investigating the operating conditions of the pick cutter under actual cutting conditions, the specifications of the machine were set to simulate field conditions, and the testing apparatus was designed. A finite element analysis was conducted to investigate the structural stability of the machine. After the verification of the design through numerical modeling, the test unit was manufactured. Validation tests were conducted on various rock samples. The results confirmed that the abrasion testing machine effectively followed the designated pre-designed spiral path. This paper, therefore, proposes a pin-on-disk type abrasion testing method which can simulate the actual abrasion phenomenon on the real cutting conditions (i.e., force and velocity) of rock cutting tools.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23

Similar content being viewed by others

References

  1. Neil DM, Rostami J, Ozdemir L, Gertsch R (1994) Production estimating techniques for underground mining using roadheaders. Preprints-Society of Mining Engineers of Aime.

  2. Rostami J, Ozdemir L, Neil DM (1994) Roadheaders performance optimization for mining and civil construction. In Proceedings of the 13th annual technical conference, Institute of Shaft Drilling Technology (ISDT), 18–21.

  3. Bilgin N, Yazici S, Eskikaya S (1996) A model to predict the performance of roadheaders and impact hammers in tunnel drivages. In ISRM International Symposium-EUROCK 96. International Society for Rock Mechanics and Rock Engineering.

  4. Bilgin N, Tumac D, Feridunoglu C, Karakas AR, Akgul M (2005) The performance of a roadheader in high strength rock formations in Küçüksu tunnel. In Materiały konferencyjne. 31th ITA-AITES World Tunnel Congress, Instanbul.

  5. Copur H, Ozdemir L, Rostami J (1998) Roadheader applications in mining and tunneling industries. Preprints-society of mining engineers of AIME.

  6. Thuro K, Plinninger RJ (2003) Hard rock tunnel boring, cutting, drilling and blasting: rock parameters for excavatability. In 10th ISRM Congress. International Society for Rock Mechanics and Rock Engineering.

  7. Balci, C., Demircin, M. A., Copur, H., & Tuncdemir, H. (2004). Estimation of optimum specific energy based on rock properties for assessment of roadheader performance. Journal of The Southern African Institute of Mining and Metallurgy, 104(11), 633–641

    Google Scholar 

  8. Wang, L., Kang, Y., Zhao, X., & Zhang, Q. (2015). Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis. Tunnelling and Underground Space Technology, 50, 324–333

    Article  Google Scholar 

  9. Robbins, R. J. (2000). Mechanization of underground mining: a quick look backward and forward. International Journal of Rock Mechanics and Mining Sciences, 37(1–2), 413–421

    Article  Google Scholar 

  10. Blindheim OT, Grov E, Nilsen B (2002) The effect of mixed face conditions (MFC) on hard rock TBM performance. In AITES-ITA Downunder: 28th ITA General Assembly and World Tunnel Congress, Sydney, Australia: Modern Tunnels-Challenges and Solutions, Institution of Engineers, 440

  11. Fowell RJ, Abu Bakar MZ (2007) A review of the Cerchar and LCPC rock abrasivity measurement methods. In 11th Congress of the International Society for Rock Mechanics, Second half century for rock mechanics, 1, 155-160

  12. Hassanpour, J., Rostami, J., Khamehchiyan, M., Bruland, A., & Tavakoli, H. R. (2010). TBM performance analysis in pyroclastic rocks: a case history of Karaj water conveyance tunnel. Rock Mechanics and Rock Engineering, 43(4), 427–445

    Article  Google Scholar 

  13. Baker RN, Shen Y, Zhang J, Robertson SD (2010) New cutter technology redefining PDC durability standards for directional control: North Texas/Barnett Shale. In IADC/SPE Drilling Conference and Exhibition. Society of Petroleum Engineers.

  14. Murphy DJ, Tetley NP, Partin UT, Livingston D (2010) Deepwater drilling in both hard and abrasive formations; the challenges of bit optimisation. In North Africa Technical Conference and Exhibition. Society of Petroleum Engineers.

  15. Kim, E., Rostami, J., Swope, C., & Colvin, S. (2012). Study of conical bit rotation using full-scale rotary cutting experiments. Journal of Mining Science, 48(4), 717–731

    Article  Google Scholar 

  16. Izbinski K, Patel SG, Van Deven A (2015) Innovative Dual-Chamfer Edge Technology Leads to Performance Gains in PDC Bits. In SPE/IADC Drilling Conference and Exhibition. Society of Petroleum Engineers.

  17. ASTM Standard G132 (2010) Standard test method for laboratory determination of abrasiveness of rock using the Cerchar method

  18. Alber M, Yaralı O, Dahl F, Bruland A, Käsling H, Michalakopoulos TN, Cardu M, Hagan P, Aydın H, Özarslan A (2013) ISRM suggested method for determining the abrasivity of rock by the CERCHAR abrasivity test. In The ISRM Suggested Methods for Rock Characterization, Testing and Monitoring: 2007–2014. 101–106

  19. Thuro K, Singer J, Kasling H, & Bauer M (2007) Determining abrasivity with the LCPC test. In 1st Canada-US Rock Mechanics Symposium. American Rock Mechanics Association.

  20. Lien R (1961) An indirect test method for estimating the drillability of rocks. Doctorate Dissertation, NTH Department of Geology, Norway.

  21. Bruland A, Dahlo TS, Nilsen B (1995) Tunnelling performance estimation based on drillability testing. In 8th ISRM Congress. International Society for Rock Mechanics and Rock Engineering.

  22. Bruland A (2000) Hard rock tunnel boring. Fakultet for ingeniørvitenskap og teknologi.

  23. Nilsen B, Dahl FE, Holzhauser J, Raleigh P (2006) Abrasivity of soils in TBM tunnelling. Tunnels & Tunnelling International.

  24. Nilsen B, Dahl F, Holzhäuser J, Raleigh P (2006) Abrasivity testing for rock and soils. T & T international, 47–49.

  25. Nilsen B, Dahl F, Holzhäuser J, Raleigh P (2006) SAT: NTNU's new soil abrasion test. T & T international, 43–45.

  26. Goktan, R. M., & Gunes, N. (2005). A semi-empirical approach to cutting force prediction for point-attach picks. Journal of the Southern African Institute of Mining and Metallurgy, 105(4), 257–263

    Google Scholar 

  27. Bilgin, N., Demircin, M. A., Copur, H., Balci, C., Tuncdemir, H., & Akcin, N. (2006). Dominant rock properties affecting the performance of conical picks and the comparison of some experimental and theoretical results. International Journal of Rock Mechanics and Mining Sciences, 43(1), 139–156

    Article  Google Scholar 

  28. Gertsch L, Summers D (2006) Disc cutting of low-strength brittle rock. In Golden Rocks 2006, The 41st US Symposium on Rock Mechanics (USRMS). American Rock Mechanics Association.

  29. Balci, C., & Bilgin, N. (2007). Correlative study of linear small and full-scale rock cutting tests to select mechanized excavation machines. International Journal of Rock Mechanics and Mining Sciences, 3(44), 468–476

    Article  Google Scholar 

  30. Bakar, M. Z. A., & Gertsch, L. S. (2013). Evaluation of saturation effects on drag pick cutting of a brittle sandstone from full scale linear cutting tests. Tunnelling and Underground Space Technology, 34, 124–134

    Article  Google Scholar 

  31. Choi, S. W., Chang, S. H., Park, Y. T., & Lee, G. P. (2014). Performance estimation of conical picks with slim design by the linear cutting test (I): Depending on attack angle variation. Journal of Korean Tunnelling and Underground Space Association, 16(6), 573–584

    Article  Google Scholar 

  32. Choi, S. W., Chang, S. H., Lee, G. P., & Park, Y. T. (2014). Performance estimation of conical picks with slim design by the linear cutting test (II): Depending on skew angle variation. Journal of Korean Tunnelling and Underground Space Association, 16(6), 585–597

    Article  Google Scholar 

  33. Kang, H., Cho, J. W., Park, J. Y., Jang, J. S., Kim, J. H., Kim, K. W., Rostami, J., & Lee, J. W. (2016). A new linear cutting machine for assessing the rock-cutting performance of a pick cutter. International Journal of Rock Mechanics and Mining Sciences, 88, 129–136

    Article  Google Scholar 

  34. ASTM Standard G-99 (2016) Standard Test method for Wear Testing with a Pin-on-Disk Apparatus

  35. Blau, P. J., & Budinski, K. G. (1999). Development and use of ASTM standards for wear testing. Wear, 225, 1159–1170

    Article  Google Scholar 

  36. Blickensderfer, R., & Laird, G. (1988). A pin-on-drum abrasive wear test and comparison with other pin tests. Journal of Testing and Evaluation, 16(6), 516–526

    Article  Google Scholar 

  37. Hisakado, T., Miyazaki, K., Kameta, A., & Negishi, S. (2000). Effects of surface roughness of roll metal pins on their friction and wear characteristics. Wear, 239(1), 69–76

    Article  Google Scholar 

  38. Penagos, J. J., Ono, F., Albertin, E., & Sinatora, A. (2015). Structure refinement effect on two and three-body abrasion resistance of high chromium cast irons. Wear, 340, 19–24

    Article  Google Scholar 

  39. Paez CVG (2014) Performance, wear and abrasion in excavation mechanized tunneling in heterogeneous land. PhD thesis. Universitat Politècnica de Catalunya (UPC).

  40. Farrokh, E., & Kim, D. Y. (2018). A discussion on hard rock TBM cutter wear and cutterhead intervention interval length evaluation. Tunnelling and Underground Space Technology, 81, 336–357

    Article  Google Scholar 

  41. Bressan, J. D., Hesse, R., & Silva, E. M., Jr. (2001). Abrasive wear behavior of high speed steel and hard metal coated with TiAlN and TiCN. Wear, 250(1–12), 561–568

    Article  Google Scholar 

  42. Gonzalez, C., Martin, A., Llorca, J., Garrido, M. A., Gomez, M. T., Rico, A., & Rodriguez, J. (2005). Numerical analysis of pin on disc tests on Al–Li/SiC composites. Wear, 259(1–6), 609–612

    Article  Google Scholar 

  43. Bressan, J. D., Battiston, G. A., Gerbasi, R., Daros, D. P., & Gilapa, L. M. (2006). Wear on tool steel AISI M2, D6 and 52100 coated with Al2O3 by the MOCVD process. Journal of Materials Processing Technology, 179(1–3), 81–86

    Article  Google Scholar 

  44. Thomann, U. I., & Uggowitzer, P. J. (2000). Wear–corrosion behavior of biocompatible austenitic stainless steels. Wear, 239(1), 48–58

    Article  Google Scholar 

  45. Kim, E. (2015). Effect of skew angle on main precursor of frictional ignition in bench-scale simulation of excavation processes. International Journal of Rock Mechanics and Mining Sciences, 80, 101–106

    Article  Google Scholar 

  46. Kim, E., Hirro, K., Oliveira, D., & Kim, A. (2017). Effects of the skew angle of conical bits on bit temperature, bit wear, and rock cutting performance. International Journal of Rock Mechanics and Mining Sciences, 100, 263–268

    Article  Google Scholar 

  47. Mahmood IA, Moheimani SR (2010) Spiral-scan atomic force microscopy: A constant linear velocity approach. In 10th IEEE International Conference on Nanotechnology, IEEE, 115–120.

  48. Ziegler, D., Meyer, T. R., Amrein, A., Bertozzi, A. L., & Ashby, P. D. (2016). Ideal scan path for high-speed atomic force microscopy. IEEE/ASME Transactions on Mechatronics, 22(1), 381–391

    Article  Google Scholar 

  49. Sang, X., Lupini, A. R., Unocic, R. R., Chi, M., Borisevich, A. Y., Kalinin, S. V., Endeve, E., Archibald, R. K., & Jesse, S. (2017). Dynamic scan control in STEM: Spiral scans. Advanced Structural and Chemical Imaging, 2(1), 6

    Article  Google Scholar 

  50. Snowdon, R. A., Ryley, M. D., & Temporal, J. (1982). A study of disc cutting in selected British rocks. International Journal of Rock Mechanics and Mining Sciences and Geomechanics Abstracts, 19(3), 107–121

    Article  Google Scholar 

  51. Yagiz, S. (2008). Utilizing rock mass properties for predicting TBM performance in hard rock condition. Tunnelling and Underground Space Technology, 23(3), 326–339

    Article  Google Scholar 

  52. Hassanpour, J., Rostami, J., Khamehchiyan, M., & Bruland, A. (2009). Developing new equations for TBM performance prediction in carbonate-argillaceous rocks: a case history of Nowsood water conveyance tunnel. Geomechanics and Geoengineering: An International Journal, 4(4), 287–297

    Article  Google Scholar 

  53. Salimi, A., & Esmaeili, M. (2013). Utilising of linear and non-linear prediction tools for evaluation of penetration rate of tunnel boring machine in hard rock condition. International Journal of Mining and Mineral Engineering, 4(3), 249–264

    Article  Google Scholar 

  54. Macias FJ, Jakobsen PD, Bruland A, Log S, Grøv E (2014) The NTNU prediction model: a tool for planning and risk management in hard rock TBM tunnelling. In World tunnelling congress.

  55. Macias FJ, Wilfing L, Andersson T, Thuro K, Bruland A (2015) Performance and cutter life assessments in hard rock tunnelling. In ISRM Regional Symposium-EUROCK. International Society for Rock Mechanics and Rock Engineering

  56. Dehnavi RN, Sadeghi M, Bardaran E, Ebrahim MB (2016) The performance of a TBM in difficult ground conditions of golab water transfer tunnel: a case study in Iran, 2nd International Conference on Tunnel Boring Machines in Difficult Grounds.

  57. Macias FJ, Dahl F, Bruland A (2017) International Tunnelling and Underground Space Association (ITA). Applicability of the new rock abrasivity test method (RIAT) to cutter life assessments in hard rock tunnel boring. In World Tunnel Congress, 1–10

  58. Hassanpour, J., Esmaeili Vardanjani, S., Cheshomi, A., & Rostami, J. (2019). Engineering geological studies used for redesigning and employing a hard rock TBM in soft rock formations of Chamshir water conveyance tunnel. Geopersia, 9(1), 1–20

    Google Scholar 

Download references

Acknowledgements

This research was supported by a grant (21CTAP-C164190-01) from Technology Advancement Research Program (TARP) funded by Ministry of Land, Infrastructure and Transport of Korean government.

Author information

Authors and Affiliations

  1. Construction Equipment Technology Center, Korea Institute of Industrial Technology, Gyeongsan-si, Gyeongsangbuk-do, Republic of Korea

    Dae-ji Kim, Chang-Heon Song, Joo-Young Oh & Jung-Woo Cho

  2. Advanced Instrumentation Institute, Korea Research Institute of Standards and Science, Daejeon, Republic of Korea

    Hoon Kang

  3. Department of Mining Engineering, Colorado School of Mine, Golden, CO, 80401, USA

    Jamal Rostami

Authors
  1. Dae-ji Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hoon Kang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chang-Heon Song
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Joo-Young Oh
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jung-Woo Cho
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jamal Rostami
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jung-Woo Cho.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kim, Dj., Kang, H., Song, CH. et al. Design of Pin-on-Disk Type Abrasion Testing Machine for Durability Assessment of Rock Cutting Tools. Int. J. Precis. Eng. Manuf. 22, 1249–1270 (2021). https://doi.org/10.1007/s12541-021-00534-w

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-021-00534-w

Keywords

Search

Navigation