Int. J. Rock Mech. Min. Sci. & Georaech. Abstr. Vol. 12. pp. 361-366. Pergamon Press 1975.

Printed in Great Britain

Rock Excavation by Disc Cutter

F R A N K F. R O X B O R O U G H *
H U W R. P H I L L I P S t
Partial factorial experiments have been undertaken to study the effect of
changing the principal geometrical variables on the performance of disc
cutters operating in both the unrelieved and relieved cutting modes.
A simple mathematical model is proposed which, on the evidence of the
experimental data, is found to provide a good description of the magnitude
and variation of thrust and rolling forces with disc diameter, edge angle
and penetration. Further analysis shows the maximum separation between
adjacent discs operating in array to be governed by the compressive to
shear strength ratio for the rock.
An examination of the published results of others in this field supports
the belief that the disc model is valid.

INTRODUCTION R o c k samples for the experimental work were

obtained from an exposure which represented the
The design of tunnel boring machines which use disc
Bunter at something close to its strongest condition.
cutters as the primary means of rock excavation has
Petrographic examination showed the rock to contain
not, until recent years, had the support of a concerted
uniformly distributed subrounded grains of predomin-
research effort into fundamental aspects of rock
antly quartz and feldspar producing a h o m o g e n e o u s
breakage with free rolling tools. Lately some valuable
rock with an isotropic fabric. It is classified as a
work has been carried out which has provided a useful
'mature lithic arenite'[5] and has the following
insight into the p e r f o r m a n c e of discs, but this has
measured properties
generally involved single, or at most two, variable
studies in a range of r o c k s [ I - 3 ] . Such work has,
therefore, tended to emphasise rock type as the TABLE !. BUNTER SANDSTONE PROPERTIES
principal variable, which is certainly important in
No. of
defining the practical scope and performance expecta- Test tests V a l u e + S.D.
tion for this type of tool, but it provides little
knowledge on how the several design and operational Unconfined compressive strength MN/m2 I0 49.20_+0.67*
Unconfined tensile strength MN/m2 10 2-64 +__0.15t
variables of a disc cutter influence its p e r f o r m a n c e in a Unconfined shear strength MN/m2 5 7-34 - 0.26:~
single rock. Static modulus MN/m2x 103 5 10.26- 0.24
This paper describes experiments undertaken with Dynamic modulus MN]m2x 10~ 5 11.83- 0.11
Dry bulk density (g/&) I0 2.03 _+0-02
disc cutters in one rock type, the Bunter Sandstone, True porosity % 3 22.84
and investigates the influence of five principal Grain size mm -- 1.5
variables on several criteria of performance. A simple Quartz content % -- 82
Internal friction angle° -- 22-28
theoretical derivation of the forces acting on a disc is Schmidt rebound number 25 51-7 - 1.1
offered and examined alongside experimental data for Shore hardness 40 37-3 --+8.2
the Bunter Sandstone and the published results of Impact strength index 5 42.1 + 0-4
other workers in the same field[l]. * Cylindrical specimens, 41-3 mm dia x 82.6 mm high.
t Disc specimens, 74-5 mm dia x 32.7 mm thick.
~:Rectangular prisms, 25 x 25 x 80 mm.
BUNTER SANDSTONE
This is an important rock formation in Britain,
representing roughly half of the Trias. It outcrops over
PROGRAMME OF EXPERIMENTS
much of the Midlands and North o f England and
extends in many places to thicknesses approaching To establish a reliable empirical relationship be-
1000m f4]. With several major conurbations and cities tween a variable and parameter, it has previously been
located on the Bunter outcrop, tunnelling capability in found necessary to study the effect at not less than 5
this formation is a matter of some importance. levels and where possible to arrange the levels of each
variable in arithmetical progression[6].
Of the several variables likely to influence the
* Professor of Mining Engineering, University of New South p e r f o r m a n c e of disc cutters, the following were
Wales, (formely Reader in Mining Engineering, University of
Newcastle upon Tyne). considered to be the most important. The levels
÷ Senior Research Associate, University of Newcastle upon Tyne. chosen for each variable are also listed.

ROCK |2/12--B 361

362 F.F. Roxborough and H. R. Phillips

(1) Diameter, D = 100, 125, 150, 175, 200 mm; The experimental procedure involved setting the
(2) Penetration, P = 2, 4, 6, 8, 10 mm; disc at the required level of penetration and then
(3) Edge angle, ~b = 60, 70, 80, 90, 100°; moving it, under power, into and across the surface of
(4) Cutting speed, v = 76, 102,127, 152, 178 mm/sec; the rock specimen. The thrust and rolling forces acting
(5) Spacing, S = 12, 24, 36, 48, 60 mm. on the disc during cutting were continuously measured
and recorded.
Variables (1-4) are c o n c e r n e d with single unrelieved Instrumentation included a solid plate dynamometer
disc operation, whereas (5) spacing, involves a capable of resolving the force acting on the disc into 3
determination of the optimum separation of adjacent mutually perpendicular components. This was equip-
tools in an array. ped with 24 resistance strain gauges arranged in 3
Since there is a strong possibility of interaction networks. Outputs from the 3 bridges were fed via
between some of the variables, it would normally be amplifying an integrating circuitry to a S.E. System
necessary to undertake a full factorial experiment 4000 u.v. galvanometer recorder. Power input to the
involving all interacting variables. Full factorial system was from a 5.8 V, 3 kHz stabilised supply.
coverage of 5 variables each at 5 levels would have
involved 12,500 cutting tests, allowing a minimum of 4
T H E O R E T I C A L ANALYSIS OF DISC FORCES
replications.
An experiment of this size was unmanageable and It is not difficult to appreciate that the forces
recourse was made to partial factorial planning. involved in cutting with a disc will be influenced by its
P r o t o d y a k o n o v & T e d e r have developed a technique geometry and the strength of the rock it is required to
of systematic sampling of an experimental matrix penetrate.
based on orthogonal Latin Squares and their method An elementary analysis of the mechanics of disc
was used for this experiment. A full description of the operation can be provided by invoking several assump-
method, which includes procedures for establishing tions and approximations, none of which depart too
empirical equations, appears elsewhere[6, 7]. far from reality, but the introduction of which
The parameters of disc performance are listed and considerably enhances mathematical simplicity.
defined: Consider, as shown in Fig. 1, a disc of edge angle 4~
(a) Thrust force F T - - t h e average force required to and diameter D, penetrating a rock surface to a depth
be applied perpendicular to the direction of rolling, to ' p ' under the action of a force F~.
maintain the disc at the prescribed level of penetration As penetration increases, so does the chord length
(units kN). of contact 'l' such that
(b) Rolling force F R - - t h e average force required to
be applied in the direction of cutting to cause the disc I = 2V'Dp - p2. (1)
to roll at the prescribed level of penetration (units kN).
(c) Yield, Q - - t h e volume of rock excavated by the It is assumed that the resistance to penetration is
disc per unit distance cut (units m3/km). essentially compressive and that the force FT is
(d) Specific energy, E s - - t h e work done per unit equivalent to a compressive stress acting over the
volume of rock cut (units M J/m3). projected area of disc contact " A ' . A precise
determination of area A involves a complex expres-
sion, which to a first approximation can be simplified
CUTTING RIG AND INSTRUMENTATION
with negligible loss of accuracy to:
The cutting rig used in these experiments was an
extensively modified linear shaping machine. A stiff
A = 2 p l tan -~ (2)
box-sectioned f r a m e w o r k had been fitted over the 2
cutting table to provide a track to both constrain and
guide the disc during its forward motion. The frame The thrust force to effect a penetration ' p ' m a y ,
limited the deflection of the tool during cutting to therefore, be written:
under 0.5 mm at vertical loads of up to 50kN. A
further modification was the replacement of the F~- = 4or tan ~ X/Dp 3 - p ", (3)
normal driving mechanism by a power pack and
hydraulic ram providing a stroke of 800ram and
maximum in-line force of 50 kN. Hydraulic power was
supplied by a swash plate pump driven by a 7.5 kW
motor and capable of generating cutting speeds of up
to 200 mm/sec.
A rock specimen of maximum dimensions 0-5 m
square by 0-3 m high could be a c c o m m o d a t e d by the
machine. The disc, mounted in a bearing housing, was
bolted to a triaxial force d y n a m o m e t e r which was
firmly attached to the end of the machine crosshead. Fig. 1. Geometry of disc penetration.
 Rock Excavation by Disc Cutter 363

where tr is the unconfined compressive strength of the also

rock.
Further analysis depends on the assumption that the __
D
----p
value of F r remains constant when the disc is made to O__~g= 2
roll. oa D
This assumption is vindicated by Fig. 2 which is an 2
analog trace of the static penetration force and
thereafter the same force measured while the disc is = cos 20
rolling. It shows peak values of F~ to be substantially
the same for the static and rolling conditions. Since it 1 - tan 2 0
is o b s e r v e d in practice that the broken rock behind the = 1 + tan 2 0 '
disc remains in place, it is reasonable to suppose that
the buried sector of the disc remains in bearing contact hence
with the surfaces of the cut groove during rotation.
An equation for the rolling force FR may now be
tan 2 0 = D p p
obtained.

30 Cutting direction

Fig. 2. Ultra-violet trace of thrust force for stationary and rolling conditions.

Figure 3 represents a disc under the action of the 2 or

principal forces FT and FR. If the disc is free rolling
and neglecting friction, then the line of action of the
resultant R must pass through the centre of rotation to
satisfy the zero net torque condition.
If, now, R is assumed to act at the centre of the arc and combining equations (3) and (5)
of contact a c b then for zero torque

F. 4trp 2 tan ~. (6)

F~ . of = k~. oe,

so that Ignoring friction is of little consequence to the

F~ derivation of equation (6) since its inclusion would
FR cot ~, (4) modify equation (5) thus

- p
/\ Fr = •fD
P -- • (7)

( FR 1 + / Z ~ / p

Rolling friction is likely to be the most appropriate

coefficient and with a value of less than 0.01 the
difference between equations (5) and (7) will be
negligible, [8].
Equations (3) and (6) have been used to determine
b
theoretical values for FT and FR under the action of
Fig. 3. Orthogonal forces acting on a disc. each of the disc variables.
364 F. F. Roxborough and H. R. Phillips
EXPERIMENTAL RESULTS
although again the theoretical rolling force has a
Experimental data have been abstracted from two magnitude somewhat greater than the measured data.
partial factorial matrices to provide graphical relation- Figure 5b shows yield to increase as the square of
ships between the specified parameters and each of the penetration and is precisely described by the equation
5 variables. The theoretical curves are superimposed 4' = p2 tan 0 per unit cutting distance and in which 0
where appropriate. is the breakout angle of the rock.
It should be noted that for the unrelieved disc Specific energy is greatly influenced by penetration
experiments each variable is in turn considered at the as shown by Fig. 5b. The improvement in cutting
mean level of the other 3 variables. Spacing results efficiency is most p r o n o u n c e d over the initial levels of
were abstracted from a second experimental matrix, penetration but there is a strong indication that the
which was undertaken to avoid the concept of mean reduction in Es does not continue indefinately. An
spacing implicit in a larger single matrix and thereby ultimate minimum value at a penetration of between 15
providing, via the first matrix, true unrelieved cutting and 20 mm seems to be indicated.
conditions.
3. Effect of edge angle
1. Effect of disc diameter Both F~ and FR are shown by Fig. 6a to increase
The effect of diameter of FT and FR is shown in Fig. with edge angle in much the same way as the
4a. theoretical equations prescribe.
Whereas FT is found to increase with diameter, FR
remains constant. The corresponding theoretical 60 -(a) 6c (b) 05

curves are seen to agree well in both trend and Meosured ~E

..... Theoreficol

y
magnitude with the measured data, although the fact Z
4C Fr ~ ~c
that the theoretical FR is greater than the measured ) . 2 ~ ~"
E
value should be noted. Reasons for this will be
u
considered later. o
u
2O 9r ~
EL 2C
Rock yield as shown in Fig. 4b is independent of G

diameter and since F , is similarly unaffected, specific - _ _ _ - - - - F R u3

energy should also be constant. Figure 4b shows this o ~ o l 1 l J I

50 60 70 80 90 ~00 50 60 70 80 90 J00
to be the case. Disc edge o n g l e ° Disc edge o n g l e *

(o)
Meosured
Fig. 6. Effect of disc edge angle.
6C - ( b )
--- Theoreficol

3C
E Theoretical values of rolling force follow the same
4C O O 02 -.. trend as the measured data, but as was also the case
FT/ /
. 2c
c x~x
with diameter and penetration, the magnitude differs.
u
o u 2( O.I --~
The persistently higher theoretical rolling force
LL
)- derives from the assumption that the resultant force in
FR . . . . . . . . . . Fig. 3 acts at the mid point of the arc of contact acb. In
I ~ I
50 ioo 150 200 "~0 I00 150 200 reality R will originate at a point somewhere between
Disc diometer, mm DiSC d i o m e t e r , c and b. The effect of this shift will be to increase of
and reduce oe therereby producing an increase in the
Fig. 4. Effect of disc diameter.
FT/FR ratio. A small movement of this origin would
clearly result in an appreciable change of ratio.
2. Effect of penetration Figure 6b shows that yield is independent of edge
Penetration, as shown in Fig. 5a, causes a rapid angle implying that the breakout angle of the rock is
increase in both F r and FR. constant and, therefore, specific energy can be
Both of the measured curves agree quite well in expected to, and does, increase in similar fashion to
magnitude and trend with the theoretical equations F,.

6C -(o) c ec-(b) ~6 4. Effect of cutting speed

Measured /~ r
.... The°retlco' / ~ :f ~E Thrust and rolling force, yield and specific energy
/ -..
are all unaffected by cutting speed as shown by Figs.
4.,E 7a and b.
This is consistant with the behaviour of other types
2( ~2 _~ of cutting tool in a range of rocks[9, 10]. A significant
7 t u
~_ dynamic effect seems probable only at speeds
approaching the rate of crack propagation in the rock.
2 4 6 O iO 2 4 6 8 I0 Mechanical cutting, covering the speed range normally
Penetration, mm Penefra?ion, mm associated with excavating machinery, is a quasi-static
Fig. 5. E f f e c t of p e n e t r a t i o n . operation.
 Rock Excavation by Disc Cutter 365

%
-.. 5 c - (b] Fs = F cos
Fso
--O u' C, O "'
4o[- (o) 4(

Q o F r
and (8)
',-' o ~ 3( x ,~ O x m
x ^ E
• 2o ®
,Q 2d 9~
.,,=_ FT = 2 F sin ~b
FR ~, ,o P_ 2
>-

h / I I I
so that
050 i~ I o 200 °~o Ioo 15o 2

Cutting speed, rnrn/sec Cuffing speed, rnm/sec F~

f s = - - (9)
Fig. 7. Effect of cutting speed. 2 tan -~"

5. Effect of spacing Assuming as for equation (3) that FT is equivalent to

The effect of spacing on F r and FR is shown in Fig. a compressive stress acting over the projected surface
8a. It is reasonable to expect both forces to be zero at area and for a disc contact length l:
zero spacing, which is equivalent to a disc cutting
exactly in the shadow of the tool producing the
FT=2Ptan{ • l.tr (10)
relieving groove.
As spacing increases from this limiting situation so
do thrust and rolling forces. Initially the rate of where tr is the compressive strength of the rock and
increase is high, but as the spacing becomes larger,
both forces tend to a constant value, which in the case 2~
(a) Fr
of Fig. 8a is reached at between 40 and 45 ram, beyond
2C
which interaction ceases and the disc is effectively Z
operating in isolation. The limit of interaction, of say
42.5 mm, is peculiar to the mean penetration level of
o
6 mm. Obviously a shallower penetration would reduce u_

the maximum interaction spacing and conversely a • x

higher penetration would increase it.

I 41o L I
For this reason spacing is normally combined with 20 60 8O

penetration to provide the ratio S/P, which in the case Spacing, mm

of Fig. 8a defines the limit of interaction as S / P = 7.
The variation of yield with spacing is illustrated to 2C

best effect by expressing it as a multiple of the yield

obtained from the equivalent disc operating unre- I-5

lieved. This introduces the parameter QR/Qu where

QR and Qu are the relieved and unrelieved yields
~J~ ,c
respectively. Figure 8b shows how this ratio varies 0

with S/P.
As SIP increases from zero, the yield ratio 0"5
increases and reaches unity (i.e. QR = Qu) at SIP = 3.
Continuing beyond this point, the yield ratio increases I I I
to a clearly defined maximum of about 2 when S[P is io 20 5o

approximately 7. Thereafter the yield falls abruptly to S/p

a ratio of 1 at roughly the same SIP value and remains
at unity for all higher levels of S/P.
This sudden 'cut-off' of disc interaction when
SIP = 7 is of significance• There was evidence during ~E
8°I
60
(c)

.~L:.!o_~o°
the experimental work of breaking by 'slabbing' of the ( 90*
rock between adjacent grooves when the disc spacing
ratios were between roughly 3 and 7, which coincides ~, 40 70 °

almost exactly with the points at which the yield ratio QJ 60 °

first exceeds unity and returns to it. This slabbing

o
effect has been observed elsewhere Ill]. 2O

Such breakage implies a shearing of the rock across g

Q.
I/3
a surface extending between the centre of each groove
and at the full depth of penetration. I I i
I0 20 30
If, as indicated by Fig. 1, the rock shears across the Slp
horizontal plane bounded by ab then with the usual Fig. 8. (a) Effect of spacing on disc forces. (b) Yield ratios for
notation and if Fs is the shearing force: relieved cutting. (c) Effect of spacing on specific energy.
366 F . F . R o x b o r o u g h a n d H. R. Phillips

(o) Tennessee Marble (b) Indiana limestone-2

80
A f t e r M,B and L
80 /~ A f t e r M,B and L
.... T h e o r e f i T / / @ : 90 o . . . . Theoretical

Z
60
/j/o60°
/ / 60
/~:90 ~

40
- // // 40--
o
7 qb =60 °

20 _

20-
JE
//<z
'0"/ l 1 I
2 4 6 0 2 4 6
Penetration, mm Penetration, mm

Fig. 9. Comparison of disc force analysis with the results of Morrell, Bruce and Larson.

c o m b i n i n g (9) and (I0) responding curves for Indiana Limestone--Type 2

fir = 6 9 M N / m 2) w h i c h a r e s h o w n in Fig. 9b also
F s = P . l. or. (11) provide good agreement.
Further analysis of these and the other results for 3
A l s o , if t h e r o c k fails in s i m p l e s h e a r d u e to F s t h e n m o r e r o c k s i n d i c a t e t h a t F r a n d FR v a l u e s d e t e r m i n e d
b y e q u a t i o n s (3) a n d (6), a r e r e a l i s t i c a n d c a n b e u s e d ,
F s = S . I. • (12) w i t h a f a i r d e g r e e o f c o n f i d e n c e , to d e t e r m i n e the
m a g n i t u d e o f the p r i n c i p a l f o r c e s a c t i n g on a disc.
w h e r e ~- is t h e s h e a r s t r e n g t h of t h e r o c k . E q u a t i n g (11) F u r t h e r m o r e , t h e e q u a t i o n s a r e f o u n d to g i v e a r e l i a b l e
a n d (12) n o w gives i n d i c a t i o n of h o w t h e m a g n i t u d e o f t h e d i s c f o r c e s will
v a r y with tool g e o m e t r y a n d p e n e t r a t i o n .
S o"
- (13)
P r" Acknowledgements--The research described in this paper is part of
a major investigation into the cutting characteristics of several rock
formations sponsored by the Transport and Road Research
T a b l e 1 gives the v a l u e s f o r tr a n d ~- as 49.2 a n d
Laboratory of the Department of the Environment. The authors
7.3 M N / m 2 r e s p e c t i v e l y so that, f r o m e q u a t i o n (13), wish to express their thanks to the Director for permission to
S I P = 6.7. This c o m p a r e s well with t h e m e a s u r e d c u t publish this paper. The opinions expressed are those of the authors
off S / P v a l u e of a p p r o x i m a t e l y 7. and not necessarily those of T.R.R.L.
H e n c e the m a x i m u m s e p a r a t i o n b e t w e e n a d j a c e n t Received 20 March 1975.
d i s c s in an a r r a y is e q u a l to the c o m p r e s s i v e to s h e a r
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