Estimation of optimum specific energy
based on rock properties for
assessment of roadheader performance
by C. Balci*, M.A. Demircin†, H. Copur*, and H. Tuncdemir*
classified as full-scale linear cutting test,
small-scale cutting test (core cutting),
Synopsis empirical approach, semi-theoretical approach
and field trial of a real machine.
Specific energy is defined as the amount of work required to break a The full-scale linear cutting test is widely
unit volume of rock and is used to predict the performance of
accepted and a precise approach, since a large
mechanical miners. It is obtained from full-scale rock cutting
block of rock of size 1x1x0.6 m is cut in the
experiments, which require large block samples, experienced
personnel and expensive equipment found in only a few research laboratory with an industrial cutter. The
centres in the world. cutting force, normal force, sideways force and
Estimation of the optimum specific energy, at which a given specific energy values are obtained for
geological formation is excavated at optimum cutting geometry in different cut spacing and depth values. The
the most energy efficient manner, from mechanical rock properties production rate of a mechanical miner is
to predict the performance/efficiency of roadheaders is the basic calculated based on the optimum specific
aim of this study. The mechanical rock property tests require only energy or by using a computer
core samples, which are easier to obtain and to test. In this context, model/simulation requiring forces acting on
full-scale rock cutting tests are performed on 23 different rock,
the cutters. The basic disadvantage of the full-
mineral and ore samples including sandstone, claystone, tuffite,
scale rock cutting test is that it requires large
chromite, trona and copper collected from some operating mines in
Turkey. The optimum specific energy values are obtained for each
blocks of rock samples, which are usually
sample. Physical and mechanical property tests are performed on difficult, too expensive or impossible to obtain.
the core samples obtained from the same samples to determine Also, this type of testing equipment is found in
uniaxial compressive strength, indirect (Brazilian) tensile strength, only a few research centres in the world1–3.
static and dynamic elasticity moduli, Schmidt hammer rebound Therefore, the core sample based cuttability
values, density, and Cerchar abrasivity index. The relationships tests are preferred in many cases, even though
between the optimum specific energy and the mechanical rock their predictive abilities are lower than the full-
properties are analysed using statistical methods. scale rock cutting tests.
The results indicate strong relationships between the optimum The small-scale cutting test (core cutting)
specific energy and the mechanical rock properties. The strongest
was developed by Fowell and McFeat (1976,
relationships are found by using uniaxial compressive strength and
1977)4,5. A core sample of 7.6 cm in diameter
tensile strength. The performance models developed in this study
are in good agreement with the empirical models previously or a small rock sample of 20x10x10 cm is fixed
developed for roadheaders and can be used reliably for prediction in a table of a shaping machine and cut by a
purposes. chisel pick having a rake angle of -5°, a
Keywords: Mechanical excavation, roadheader, performance clearance angle of 5°, tool width of 12.7 mm
prediction, rock cutting, optimum specific energy, mechanical and at a cutting depth of 5 mm. The test
properties of rocks. results are classified as index values and
evaluated according to previously accumulated
field performance data. The basic disadvantage
is that the predictions using this method are
based on an index cutter instead of an actual
Introduction
Prediction of the excavation performance of
any mechanical excavator such as
roadheaders, continuous miners and shearers
for any geological formation is one of the main * Istanbul Technical University, Mining Engineering
Department, Maslak, Istanbul, Turkey.
concerns in determining the economics of a
† Mineral Research and Exploration (MTA),
mechanized mining and/or tunnelling
Ankara-Turkey.
operation. There are several methods of
© The South African Institute of Mining and
performance prediction and the best approach Metallurgy, 2004. SA ISSN 0038–223X/3.00 +
may be the use of more than one of these 0.00. Paper received Jun. 2004; revised paper
methods. These methods may be generally received Sep. 2004.
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The Journal of The South African Institute of Mining and Metallurgy DECEMBER 2004 1
