Why simulate heavy machinery and mining equipment?
Large-scale systems and their structures are one-offs. Prototypes and tests are extremely resource-intensive, which is why the systems have to work right from the start. With the help of simulations, a digital twin can be created in advance, in which a large number of parameters (geometries, operating states, formations, etc.) can be tested. This makes it possible to save significant resources, costs and time in order to achieve the most efficient development possible and thus increase profitability.
The example shown depicts a tunnel boring machine (TBM). It drives through a mixed geological formation made of different materials, which are fully taken into account in the simulation.
Hydraulic cylinders press the cutting head against the rock. The rock is broken by the rotation of the drill head and the pressure of the cutter/cutting rollers. In the second video sequence, the particles without cohesion are colored red. The cutters rotate on the rock due to their rolling motion, taking into account the preload of the bearings. The removed material falls through the openings of the scrapers behind the drill head, ensuring further removal by a screw conveyor and a conveyor belt.
From this simulation, the loads (forces and moments) can be used as boundary conditions for subsequent strength analyses (FEM). This means that a precise statement can be made in advance about the system behavior, including the drill head, the cutting rollers and other components.
Simulations of slurry machines in which the face is partially or completely under water also allow different operating conditions to be taken into account.
