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A study on an up-milling rock crushing tool operation of an underwater

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Article  in  Proceedings of the Institution of Mechanical Engineers Part M Journal of Engineering for the Maritime Environment · November 2017
DOI: 10.1177/1475090217735934

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Original Article

Proc IMechE Part M:

J Engineering for the Maritime Environment
1–18
A study on an up-milling rock crushing Ó IMechE 2017
Reprints and permissions:
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DOI: 10.1177/1475090217735934

tracked vehicle journals.sagepub.com/home/pim

Mai The Vu1, Hyeung-Sik Choi2, Dae Hyeong Ji2, Sang-Ki Jeong2
and Joon-Young Kim3

Abstract
In this article, we develop the analysis of a new underwater tracked vehicle with rock crushing tool, working under the
water. To design the capacity of the underwater tracked vehicle actuator and the rock crushing tool actuator, we analyze
the interaction forces and torque between the rock and the rock crushing tool. Since experiments on the underwater
tracked vehicle with a rock crushing tool are very difficult, costly, time-consuming, we first perform a mathematical mod-
eling of the underwater tracked vehicle with the rock crushing tool. We analyze the mechanics of the underwater
tracked vehicle system that is affected by the forces and moments of the underwater rock crushing, where the force and
torque on the rock crushing tool are based on the analysis of the mechanics of an individual cutter tool. We derive a
mathematical expression for the forces and moments of the combined system on the underwater tracked vehicle and
the rock crushing tool for rock crushing. For this, we study the parameters that affect the mechanics of the underwater
tracked vehicle system with the rock crushing tool. To apply the rock crushing tool to underwater rock excavation, we
also study the hydrostatic effects to the combined underwater tracked vehicle system with the rock crushing tool. To
design the capacity of the actuator of the developing underwater tracked vehicle and the rock crushing tool, we analyze
the required tractive or down thrust forces, and the torque to the rotor carriage caused by the cutting system. In addi-
tion, we analyze the energy and the power for the rock crushing tool actuator related to the tool characteristics. To sup-
port the validity of the analyses, we use the derived equations to perform a number of numerical simulations.

Keywords
Rock crushing, underwater tracked vehicle, tractive thrust, down thrust, simulation

Date received: 25 July 2016; accepted: 11 August 2017

Introduction have been carried out. Rubinstein and Hitron2 devel-

The application of excavation machines for hard rock
excavation in both civil and mining engineering fields
has increased significantly in recent years. In particular
with the recent development of versatile machines capa-
ble of effectively coping with different rock conditions,
the mechanical excavation industry is destined to play
a much bigger role in future construction projects.
For the seafloor miner, tracked vehicles are preferred
compared to wheeled or legged vehicles due to the
larger contact area of tracks with the ground providing
better floatation and larger traction forces, which are
required for the extremely cohesive soft deep-seafloor
soil. In this reason, the interaction between ground and
off-road vehicles, such as agricultural tractors, has been
an important field of study.1 In order to investigate the
performance of tracked vehicles, a number of studies
oped a three-dimensional (3D) multi-body simulation
model for simulating the dynamic behavior of tracked
off-road vehicles using the LMS-DADS simulation pro-
gram and used user-defined force elements to describe
1
Department of Convergence Study on the Ocean Science and
Technology, School of Ocean Science and Technology, Korea Maritime
and Ocean University, Busan, Republic of Korea
2
Division of Mechanical and Energy Systems Engineering, Korea Maritime
and Ocean University, Busan, Republic of Korea
3
Division of Marine Equipment Engineering, Korea Maritime and Ocean
University, Busan, Republic of Korea
Corresponding author:
Hyeung-Sik Choi, Division of Mechanical and Energy Systems Engineering,
Korea Maritime and Ocean University, Yeongdo-ku, Busan 606-791,
Republic of Korea.
Email: hchoi@hhu.ac.kr
2 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)
the interaction between each track link and the ground.
Solis and Longoria3 described the integration of a rea-
listic and efficient track–terrain interaction model with
a multi-body dynamics model of a robotic tracked vehi-
cle, and comparisons between simulated results and
those obtained from field testing with a remotely oper-
ated unmanned tracked vehicle. Hong et al.4 developed
a simplified transient 3D dynamic analysis method for
tracked vehicles crawling on extremely soft cohesive
soil. Morgan and Cathie5 discussed aspects of terrame-
chanics and mobility that are applicable to the opera-
tion of tracked trenchers on very soft clays.
Rock crushing (RC) machines are able to perform
vertical and horizontal cuts for quarrying natural stone
mine. The design of cutting tools and setting para-
meters of cutting operations requires knowledge about
the cutting process. Cutting force is one of the main
factors characterizing a cutting process. Theoretical
evaluation of the cutting force is not an easy task. The
mechanical interaction between the cutter tool and rock
has been studied by numerous researchers over the
years. The primary motivation behind these research
efforts is twofold: on one hand, the need to improve the
efficiency of mechanical excavation of rocks, and on
the other hand, the possibility of deducing material
properties from the action of a tool pressed against the
surface of a rock. To maximize the benefits of mechani-
cal excavators to any operation, performance of these
machines under specific conditions must be understood.
For this purpose, several investigators have formulated
and applied a diversity of criteria for determining the
efficiency of mechanical techniques of excavation. The
most commonly cited criteria are bit cutting force,
power consumed, machine cutting rate, and specific
energy of the excavation process. Simple analytical
models, like those developed by Nishimatsu,6 can pro-
vide a very approximate estimation of cutting forces
only. Numerical methods based on continuum models,
like finite element methods, have serious problems in
modeling discontinuities of the material occurring dur-
ing rock cutting.7 As described by Inyang,8,9 a distinc-
tion needs to be made between the bit force needed to
penetrate rock to the depth of cut, and the force needed
to cut the rock along the cutting profile once the bit has
penetrated the rock to the depth of cut (the cutting
force).
Specific energy is one of the comprehensive criteria
for evaluating the efficiency of excavation processes. It
is inversely proportional to the efficiency of operation
and is defined as the ratio of expended energy to the
volume of material excavated. Bailey and Dean10 have
shown that when the same tool is used in fragmenting
different rocks, the specific energy is a useful basis for
comparison. However, laboratory-specific energy and
field-specific energy of excavation in the same rock can
vary by as much as 80%, as confirmed by the results of
tests performed by Rabia.11
Although there are many trenching machines which
have been manufactured by companies around the
world, information about the methods to develop such
machines is very limited because of proprietary rights
held by the companies. Moreover, the previous studies
still have some problems such as how to implement the
dynamic analysis of the total deep ocean mining system,
there is no progress in the cutter rock interaction under-
standing and modeling, and the effects are not fully
studied. Sometimes important factors are neglected,
since dynamic interaction between the cutter tools and
the rock mass is uncertain, complex, and difficult. In
industrial sectors, companies have gained numerous
experiences from designing and producing such
machines during gradual development and evolution of
successive generations of the machines. In rapid devel-
opment of trenching machine for specific operating
conditions with certain performance characteristics
requirement, an analytical approach should be devel-
oped that can cover all required important features and
yet practical. Direct experiments are time-consuming
and costly and strict scientific approach from the first
principles such as theoretical rock mechanics has
numerous difficulties such as finding detailed measured
material properties, failure criteria, or selecting which
fracture theories should be used. Regarding those con-
siderations, a modeling method for the RC tool and
further analysis of the interaction effects of underwater
RC tool to underwater tracked vehicle (UTV) is fully
studied and analyzed in this article.
Our article deals with the forces and power levels in
cutting machines having a disk or drum that rotates
about an axis perpendicular to the direction of advance.
The forces on individual cutter tools are related to their
position on the RC tool and to characteristics of tool
layout, tool speed, RC tool size, machine advance
speed, and RC tool torque. Integration leads to expres-
sions for force components acting on the RC tool axis,
taking into account tool characteristics, cutting depth
of the RC tool, and RC tool torque. These provide esti-
mates of tractive thrust and thrust normal to the pri-
mary free surface. For self-propelled machines, this
leads to considerations of traction, normal reaction,
weight, and balance. We analyze specific energy con-
sumption and relate it to machine characteristics and
strength of the material being cut. We also analyze
power requirements for the ejection of cuttings and
treat the hydrodynamic resistance of underwater cut-
tings. Finally, we conduct a number of simulations to
generate physical values for the design of the system.
General specifications of the combined
UTV with the RC tool
Underwater RC tool description
Figure 1 shows the proposed system, which consists of
a RC tool connected to a UTV, which is lowered to the
seabed by a crane. An RC tool is a machine that uses a
rotary cutting unit equipped with cutter tools (bits) to
excavate in rock for both mining and civil engineering
Vu et al.
Figure 1. An RC tool12 on the UTV.
UTV: underwater tracked vehicle; RC: rock crushing.
purposes. The cutting unit consists of a disc (or drum),
and a number of drag cutter tools spaced along its
length and wound around the disc. To excavate in
rock, the RC tool is pushed into the material, and as it
rotates while the UTV moves forward, the cutter tools
cut through the rock material. The thrust is primarily
in the direction of the rock surface advance. The rotary
action of the RC tool generates drag that is tangent to
the cutter. Thus, the cutter tools rip into the rock sur-
face and gouge off fragments.
Cutter type
A crucial aspect of any mechanical RC tool is the cutter
tool, which performs the actual rock penetration under
Figure 2. Types of cutter bits: (a) radial cutters (Sandvik) and (b) conical cutters (Kennametal).
3
a certain amount of thrust and torque provided by the
mechanical cutting system. Cutter tools are classified
into two general types: rolling cutters and drag bits.
Cutter tools transmit the energy of the machine to
the rock so that it can be fragmented. The geometry
and wear characteristics of the cutter tool therefore
have a significant effect on the energy transferred to
the rock, and the attainable rate of penetration.
The two main types of drag cutters used in the min-
ing industry employ radial and conical bits. Radial cut-
ters are limited to the excavation of the softest and
least abrasive materials. Continuous miners, long-wall
shearers, and borer miners are typical mechanical exca-
vators, where radial cutters are used to cut softer mate-
rial, such as coal, trona, and salt. Figure 2(a) shows the
examples of different radial cutters.
Figure 2(b) shows the second type of drag cutters
that use conical bits. Compared to radial bits, these are
typically used in continuous miners and long-wall
shearers to cut harder rock and are also used in road-
headers. Conical bits are more durable than radial bits
and have a self-sharpening property, which is an advan-
tage for longer cutter life compared to radial bits.
Conical bits can be used to excavate higher strength
rocks if the rock mass is significantly weakened by the
presence of joints, fractures, bedding, or foliation.
Assumptions
To simplify the challenge of modeling the RC tool, the
followings are assumed as:
 Cutting mode: up-milling RC tool mode, of which
Figure 3 shows the configuration.
4 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)
Figure 3. Cutting modes for transverse rotation devices: (a) up-milling mode, (b) climb-milling mode, and (c) slot-milling mode
(lateral view of RC tool).
 The resultant force on a single cutter tool fluctuates
with time in response to the formation of discrete
chips in the brittle material.
 In this article, the tool force does not vary systema-
tically with tool position in a homogeneous
material.
 The traverse velocity U of the UTV, when com-
pared with the RC tool tip speed ut, is small and
the absolute tool velocity u is given to a sufficient
degree of accuracy by the tangential velocity arising
from rotation alone, ut that is, u’ut = Rv = 2pRf.
 The ratio of tool force components K is assumed to
be invariant with the chipping depth of the cutter
tool.
 The tool forces are directly proportional to the
chipping depth.
Terminology
Some of the terminologies used in this article are given
below, while Figure 4 shows all the parameters used in
this article.
1. Cutting modes: Figure 3 illustrates the three main
cutting modes. In up-milling, the RC tool is sunk
into the work to a depth less than the diameter,
the axis of rotation is parallel to the primary free
surface, and the direction of rotation is such that
the cutter tools move upward on the leading side
of the RC tool. In climb milling, the RC tool is
sunk into the work to a depth less than the dia-
meter, the axis of rotation is parallel to the pri-
mary free surface, and the direction of rotation is
such that the cutter tools move downward on the
leading side of the RC tool. In the slot-milling
mode, the RC tool cuts across its complete semi-
circumference, and the axis of rotation is normal
to the primary free surface. In this article, we just
consider and analyze the interaction of a rock
crushing machine with the rock in climb-milling
operation mode.
2. Cutting depth d is the depth to which the RC tool
is set into the work, measured normal to the pri-
mary free surface.
3. Chipping depth ‘ is the depth of penetration of
the individual cutter tool into the work, measured
in a radial direction. For a given machine speed,
it varies continuously through the working sweep
of the cutter tool.
4. Effective tool length h is the maximum length of
the individual cutter tool that can safely penetrate
the work, measured in a radial direction.
5. RC tool radius R is the radius of the RC tool
measured to the effective tool tips.
6. Tracking cutters are cutter tools that sweep along
a common path in a diametral plane. The number
of the tracking cutters in a complete revolution of
the RC tool is designated by n.
Vu et al.
Figure 4. Definition of symbols (lateral view of RC tool).
7. Circumferential tooth spacing S is the circumfer-
ential distance between the tracking cutters, mea-
sured at the tooth-tip radius, that is, S = 2pR=n.
8. Lateral tooth spacing s is the distance between
adjacent rings of the tracking cutters, measured
along a generator of the RC tool.
9. Angular position of the RC tool is defined by the
angle u between a radius running through the
point of interest and a radius running normal to
the traverse direction.
10. Angular velocity of the RC tool v will often be
expressed as a frequency f in this discussion, that
is, f is the number of revolutions of the RC tool
per unit time (rev/sec).
11. Traverse rotation devices rotate about an axis that
is perpendicular to the direction of advance. It is
the motion of the entire RC tool relative to the
material being cut, that is, the motion of the cen-
ter of the RC tool.
12. The traverse speed U is the linear speed of the RC
tool center relative to the work and is directed
parallel to the primary free surface.
13. The absolute tool speed u is given by the velocity
of the tool tip relative to the work, which in turn
is given by the time derivative of the tool trajec-
tory through the work. The velocity component
derived from drum rotation alone, ut, is of special
interest. ut is the tangential velocity of the bit tip
relative to the center of the RC tool.
14. Tool forces or cutting forces are the forces devel-
oped by the individual cutter tool during the cut-
ting process. The resultant force on a cutter tool
can be resolved into tangential and radial compo-
nents fu and fR with respect to the RC tool on
which they are mounted.
15. The ratio of tool force components K is fR =fu ,
that is, the ratio of the radial component to the
tangential component. This is the tangent of
the angle between the resultant cutting force and
the tangential direction. In practical terms, it
gives a measure of the sharpness of the cutter
tool, with high values of K indicating blunt or
worn tools, also varies considerably with tool
5
design and with the state of wear, but it is not
very sensitive to variations of chipping depth ‘.13
16. RC tool cutting torque T is the net torque devel-
oped by the rotary RC tool when it applies tan-
gential cutting forces to the cutter tool tips at
constant speed.
17. Net overall cutting force Ft is the tangential force
given by Ft = T=R, where R is the radius of the
RC tool to the cutter tool tips.
18. Axle forces on the RC tool are the forces devel-
oped on the axle by the cutting process. The
resultant axle force at any instant is given by a
summation of the vector cutting forces on all the
active cutter tools. The resultant axle force can be
resolved into three components that are (1) paral-
lel to the direction of advance H, (2) normal to
the primary free surface V, and (3) radial to the
RC tool axis. The component radial to the RC
tool axis should be zero for a symmetrical RC
tool that is dynamically balanced about the mid-
section. The component parallel to the direction
of advance H, which is often horizontal, equals
the sum of the components of fu and fR resolved
in that direction. The component normal to the
primary free surface V, which is often vertical,
equals the sum of the components of fu and fR
resolved in the same normal direction.
19. Tractive thrust of a machine FTT is the force par-
allel to the traverse direction in order to overcome
cutting resistance. This equals the axle force com-
ponent H. When the rotary RC tool is mounted
on a UTV, the tractive thrust is the net forward
force developed by the wheels or crawler tracks,
that is, the ‘‘drawbar pull.’’
20. Down thrust of a machine FDT, which may be
positive or negative, is the force perpendicular to
the traverse direction that is required to maintain
the RC tool at the required operating depth. This
is equal to the axle force component V. When the
rotary RC tool is mounted on a UTV, the avail-
able down thrust is limited by the weight and bal-
ance of the machine.
21. Machine power P can be partitioned broadly as
the RC tool power Pr, thrust power PH, and
power loss PL. The RC tool power is the power
consumed by the RC tool for cutting. The thrust
power is the net power used to overcome cutting
resistance in the direction of advance. The power
loss is the power that does not contribute directly
to the cutting process.
22. Power density of a RC tool is a term used here to
denote the RC tool power per unit area of cutting
surface, that is, power density Q is PR =Rum B,
where um = cos1 ½1  (d=R) and B is RC tool
width. Since um is normally an operating variable,
an arbitrary definition of normal power density is
taken as a basis for comparison of machines;
making um = p=2, nominal power density is
2PR =pRB.
6 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)

23. Specific energy of a cutting machine is the energy sophisticated 2D cutting theories. Since analysis of the
consumed per unit volume of material removed. tool forces on rock-cutting machines is too compli-
Alternatively, it is the power consumption divided cated, the less affecting complexities and the unknowns
by the volumetric removal rate. The overall spe- are neglected. A simple approximation would make fR
cific energy for a complete machine is based on or fu proportional to the chipping depth; as a general
the total machine power. approximation, they can be expressed as
 b
‘
fu = ku ð1Þ
Analysis of force and moment of the RC r
 a
tool ‘
fR = kR ð2Þ
Mellor13 published a series of reports covering the r
mechanics of various terrestrial cutting and boring From equations (1) and (2), we have the ratio
machines that work on land such as transverse rotation between fR and fu as follows
machines, axial rotation machines, and continuous belt
 
machines. In this article, Mellor’s analytical model is fR kR ‘ ab
adopted and improved to design and to analyze an = ð3Þ
fu ku r
underwater RC machine developed at Korea Institute
of Ocean Science and Technology (KIOST). In this arti- where kR and ku are proportionality constants with
cle, some steps of the analysis process for the RC dimensions of force (embodying the effects of the cutter
machine are presented, which can be used as reference tool geometry and the rock properties), r is the radius
for designing an RC machine. The cutting process is of curvature of the cutter tool tip, and a and b are
highly nonlinear and complex. Moreover, the cutting dimensionless exponents.
process in marine environment makes the system more Some characteristics of a and b can be deduced from
complex. Because the system includes the hydrodynamic the data compiled in Mellor.13 These data show force
calculation and the shapes of typical rock materials are components either proportional to the chipping depth
very irregular, the corresponding computation is quite ‘, or approximately proportional to some fractional
complicated. In this reason, it is necessary to consider power of the chipping depth ‘. They also show fR =fu
the main influencing factors to simplify the system. decreasing slowly with increase in the chipping depth ‘,
Proper application of the RC machines to any mining from a value that is approximately equal to unity when
or engineering application depends on the detailed the chipping depth ‘ is small, that is, fR =fu ’1 when
understanding of the parameters described below. ‘4r. Hence, it might be reasoned that
a41 b41
Analysis of cutting forces a4b
The first aim of this article is to examine the forces on a’b
individual cutter tools when they are mounted on a RC
tool and then to determine how an assembly of the cut- To simplify the tool force variations during one RC
ter tools affects the moments and the forces for the RC tool rotation, assume that a = b = 1, which means that
tool as the entire of the RC tool. cutting forces are directly proportional to chipping
depth.
In the foregoing analysis, equations (1) and (2) are
Forces on individual cutter tools. Each cutter tool on a RC only approximate empirical relations, and in many
tool develops a cutting force that is determined mainly cases, the experimental data from cutting tests can be
by the cutter tool geometry, rock properties, and oper- represented adequately by linear relations of the form
ating conditions, and in particular, the chipping depth.  
Figure 4 shows that the cutting force can be resolved ‘
fR = AR + kR ð4Þ
into radial and tangential components fR and fu . r
For a particular type of cutter tool working in a  
‘
given isotropic material, both the tangential cutting fu = Au + ku ð5Þ
r
force fu and the radial cutting force fR increase as the
chipping depth ‘ increases.13 In an ideal condition, fu where AR and Au are proportionality constants with
and fR are directly proportional to the chipping depth ‘ dimensions of force, representing tool force compo-
when the chipping depth ‘ is very small with the condi- nents as ‘ tends to zero. In some circumstances, that is,
tion of ‘5w (3D cutting). However, experimental data narrow tools or tools cutting deeply in material, the
show that the general pattern of the behavior of fu and constants AR and Au are small, and it is sufficient to
fR increases nonlinearly with ‘ in two-dimensional (2D) assume direct proportionality
cutting (w  ‘). The rate of increase is dropping off as  
the chipping depth ‘ increases according to irregular ‘
fR = kR ð6Þ
parabolic relation; this is reflected in the more r
Vu et al. 7

 
‘ The total tangential force acting on the perimeter of
fu = ku ð7Þ
r the RC tool at any given time is the sum of the individ-
ual tangential tool forces.
The chipping depth ‘ is a function of the rotational fre-
quency of the RC tool f, the traverse velocity U, the
number of tracking cutters n, and the angular position u Net overall cutting force and tool force. The sum of the tan-
gential tool forces at any given time gives a net overall
U cutting force Ft that has to be overcome by the applied
‘= sin u ð8Þ torque of the RC tool under constant speed conditions.
fn
When there are only a few cutter tools on the RC tool
Thus, for a given set of operating conditions, the (n is small), Ft can be obtained by calculating the values
chipping depth of each individual cutter tool increases of fu for each of the cutters tool in the work and sum-
in proportion to sin u. With a typical up-milling the RC ming them, and plotting the results against the angular
tool, the variation is from practically zero at the point position to obtain variation of Ft with position or time.
of entry, up to a maximum that occurs at the point of However, when there are many cutter tools in the work
exit when umax \ ( p2 ), and at u ¼ p2 when umax > p2 . together, and Ft does not vary significantly with posi-
Substituting equation (8) into equations (6) and (7) tion or time, an integral expression for Ft is more
yields convenient.
Suppose that the cutter tools on a wide, rigid drum
kR U RC tool are disposed in m rings across the width of the
fR = sin u ð9Þ
r fn RC tool, and that there are n uniformly spaced cutter
ku U tools in each ring. If the m rings are staggered systema-
fu = sin u ð10Þ tically with respect to neighboring rings, then a side
r fn
view of the RC tool would show mn cutter tools uni-
In addition, we can easily deduce the ratio between formly spaced around the perimeter. With cutter tools
fR and fu as follows spaced around the RC tool, each cutter tool accounts
for an angular interval of 2p=mn, thus, the tangential
fR kR cutting force per unit angle, fu0 , is
= =K ð11Þ
fu ku
fu
Since fR and fu are proportional, it is only necessary to fu0 = ð16Þ
2p=mn
treat one component; we select fu , as it relates directly
to the torque of the RC tool. where fu = f ( sin u=n)
In general, with n cutter tools spaced uniformly in which the expression of f* is defined as follows
around the RC tool, there are n cutter tools passes ku U
through the work for each revolution, and each cutter f = ð17Þ
r fn
tool experiences a tangential force of
The net overall cutting force is thus
ku U sin u
fu = sin u = f ð12Þ uðm
r nf n
Ft = fu0 du ð18Þ
where f = (fu )u = p=2, n = 1 , that is, the maximum tangen-
0
tial force at u = p=2 when there is only one cutter tool.
At any given time, the number of cutter tools in the From equation (16), we can easily deduce the expres-
work is the integer given by sion of the net overall cutting force Ft as follows
um uðm
Na = ð13Þ mn
2p=n Ft = fu du ð19Þ
2p
0
where the angular position is given as follows
   Substituting equation of fu into equation (19) yields
1 d
um = cos 1  ð14Þ uðm
R mf
Ft = sin udu ð20Þ
where d is the cutting depth and R is RC tool radius. 2p
0
Substituting equation (14) into equation (13), we
have Then, again substituting equation (17) into equation
(20), and taking the integration, we can define as
n cos1 ½1  (d=R) follows
Na = ð15Þ
2p
8 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)

mku U of mobile machines, the available tractive thrust from

Ft = d ð21Þ
r uta the UTV can set the limit of performance for an up-
milling RC tool. In the following discussion, H will be
where uta = 2pRf is the tangential velocity of the RC
referred to dimensionless terms in the form of H/Ft,
tool, d is the cutting depth, and r is a constant in this
and to give this clearer meaning, we assume that Ft is
context.
the maximum value that can be developed when the
In principle, the RC tool torque T could be estimated
RC tool is operating at the maximum torque.
from a laboratory test that uses a single cutter tool to
The down thrust force V, which is perpendicular to
define the relationship between fu and ‘. Alternatively,
the direction of travel and to the work surface, deter-
the mean force for a single cutter tool at a given angular
mines the down thrust needed to maintain a given cut-
position could be estimated from field measurements of
ting depth d. On mobile machines, hydraulic actuators
torque T or power Pr on the RC tool, recalling that
often provide this down thrust; an upper limit to posi-
Pr tive down thrust is set by the weight and balance of the
T = Ft R = ð22Þ whole machine. If the force V exceeds the thrust capa-
2pf
bility of the actuators or the available reaction, then
So, we can easily obtain the relationship between Ft cutting depth d or forward speed U will have to change,
and fu using equation (22), as follows in order to limit V. As with H, we will discuss the force
‘u T ‘u P r V in dimensionless terms as V/Ft.
fu = = ð23Þ When the RC tool has many cutter tools acting at
md(U=uta )R mdU
the same time, as described above, each tool force can
It is also instructive to express fu as be divided by an angular interval of 2p=mn, in order to
give force per unit angle, fu0 and fR0 . At any angular
2pR position u, the unit force in the tangential direction is
fu = sin u Ft ð24Þ
nmd shown in equation (16), while the force in the radial
In addition, from equation (22), we can rearrange direction is expressed as
equation (24) as follows
fR
fR0 = ð28Þ
2p sin uT Pr sin u 2p=mn
fu = = ð25Þ
nmd nmdf
Then, substituting equation (10) into equation (16)
For d/R 4 1, the maximum tool forces occur at the and using equation (17) yields
maximum value of u. At this maximum, we have
( sin u)=d = ½(2R=d)  11=2 =R, and equation (25) can m sin u
fu0 = f ð29Þ
be defined as 2p
Similarly, substituting equation (9) into equation
2pT ½(2R=d)  11=2 (28) and using equation (17) yields
( fu )max = ð26Þ
mn R
kR m sin u
or fR0 = f ð30Þ
ku 2p
Pr ½(2R=d)  11=2 On each angular increment of the cutting perimeter
( fu )max = ð27Þ
nmf R (du), there are the radial and the tangential forces, fR0
where ( fu )max is the maximum value of time-averaged and fu0 , respectively. These forces can be resolved paral-
tangential tool force. This is an important result, in that lel to, and normal to, the travel direction.
it gives a very practical method for estimating the maxi- For an up-milling RC tool, resolution gives
mum tool force.
 Parallel to travel direction: fR0 sin u du +
0
fu cos u du;
Tractive thrust and down thrust forces on the RC tool  Normal to travel direction: fR0 cos udu fu0 sin udu.
axis. Under normal circumstances, a symmetrical RC
tool on a transverse rotation machine has no net side We obtain the forces on the axis of the up-milling
force acting parallel to the axis. The resultant force that RC tool, H and V, by summing or integrating the
acts normal to the rotation axis is, in general, inclined resolved incremental components
to the travel direction at the finite angle; it is conveni-
ent to resolve that force into components H and V, uðm
 
which are parallel and normal to the travel direction, H= fR0 sin u + f u0 cos u du ð31Þ
respectively.
0
The tractive thrust force H, which is parallel to the
travel direction, determines the tractive thrust needed Substituting equations (29) and (30) into equation
to feed the RC tool into the rock material. In the case (31) and then integrating, we finally obtain
Vu et al.
"   1=2  #
F t kR R kR d 2R d
H= um  1 1 + 2
2 ku d ku R d R
ð32Þ
Similar to calculating the tractive thrust H, we can
define the down thrust V as follows
uðm
V= ð f 0R cos u  f0 u sin uÞdu ð33Þ
0
From equations (29) and (30), then integrating equa-
tion (33), we also finally have
"     1=2 #
Ft kR d R d 2R
V= 2  um + 1  1
2 ku R d R d
ð34Þ
1
where um = cos ½1  (d=R) and kR =ku are constants,
consistent with the assumptions of equations (9)–(11).
H is positive when thrust applied by the machine is in
the direction of travel, and V is positive when thrust
applied by the machine is downward into the work.
As mentioned earlier, the ratio of the radial compo-
nent to the tangential component K is the tangent of
the angle between the resultant cutting force and the
tangential direction. The consideration of the effect of
K is important for any mechanical RC systems because
it affects machine performance directly. The following
simulation is given in order to illustrate the application
of the concepts and equations. This is based on an
actual engineering problem but is simplified to concen-
trate on the key points. Herein, H and V are expressed
as dimensionless terms in the form of H/Ft and V/Ft
and, for clarity, Ft is defined as the maximum value
that can be developed when the rotor exerts maximum
torque or is developing maximum power. The simula-
tion results of equations (32) and (34) are shown gra-
phically in Figures 5 and 6.
Figure 5 shows the influence of the ratio K = kR =ku
more directly and plots H/Ft and V/Ft against d/R for
two different values of K = kR =ku in the up-milling
mode of operation. Suppose a machine is fitted with
sharp new cutting teeth: fR = fu = kR =ku = K = 1. The
RC tool is up-milling and is operated so as to utilize
the full power available to the RC tool. With the RC
tool just touching the work surface, that is, with d close
to zero, the resistance to forward motion H/Ft would
be close to 1, and the required down thrust V/Ft would
also be close to 1 (with K = 1) and would be close to 2
(with K = 2). Setting the RC tool deeper into the work
would produce an increase in H/Ft (as might intuitively
be expected) and a decrease in V/Ft (which may not be
obvious). The increase in H/Ft is not very great; a maxi-
mum value of H/Ft = 1.37 is reached when the RC tool
is set to a depth equal to about 50% of the effective
radius, that is, at d/R = 0.5. If d is further increased,
the value of H/Ft then falls off again. As d is increased,
the vertical thrust V/Ft falls off very significantly and at
9
Figure 5. Variation of the axle force components H and V with
the cutting depth d, assuming constant torque.
d/R = 0.5, V/Ft = 0.13. If d is increased even more, V
continues to decrease, dropping to zero at d/R = 0.64,
and then becoming negative at greater depths. This
means that for d/R . 0.64, the RC tool is pulling itself
down into the work, and in order to maintain a fixed
cutting depth, the thrust actuators have to hold it back.
In principle, the depth at which V changes from posi-
tive to negative is an indication of the value of K for
the cutter tools.
Returning to consideration of the same machine in
the up-milling mode, assume that the cutter tool wear
has increased the value of K (K = fR = fu ) to 2. At d = 0,
H/Ft would start at 1.0, as it did with the unworn teeth;
but as d increases, H/Ft increases markedly, reaching at
d/R = 0.55 a value of 2, and attaining at d/R = 0.9 a
maximum value of almost 2.1. The down thrust V/Ft
would start off from a value of 2, that is, twice as big as
the value for the unworn teeth. As d increases, V/Ft
decreases, falling to a value of V/Ft = 1 at d/R = 0.425,
and not changing from positive to negative until reach-
ing a depth of d/R = 1.18.
Figure 6 shows the effect of K, which reflects the cut-
ter tool geometry, in particular the geometric changes
by wear and gives H/Ft and V/Ft as functions of K for
three different values of d/R. For shallow cutting
with d/R = 0.15 (Figure 6(a)), the effect of K on H is
not dramatic. In up-milling, as K increases from 1 to 2,
H/Ft increases from 1.28 to 1.64. There is a much stron-
ger effect on V. In up-milling, as K changes from 1 to 2,
V/Ft increases from 0.57 to 1.5. For deep cutting with
d/R = 0.75 (Figure 6(b)), as K changes, both H and V
change by approximately the same amount. In up-
milling, an increase in K from 1 to 2 increases H/Ft
from 1.34 to 2.06 and V/Ft from 20.9 to + 0.53. For
slot milling with d/R = 2.0 (Figure 6(c)), K has no
effect on V/Ft, but H/Ft increases markedly. Also, a
change of K from 1 to 2 makes H/Ft increase from 0.78
to 1.57
10 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)
Figure 6. Variation of the axle force components H and V with K, assuming constant torque and proportional tool force
components (a) shallow cutting d/R = 0.15, (b) deep cutting d/R = 0.75 and (c) slot milling d/R = 2.
Resistance forces
Other factors to be considered in the design of a RC
tool are the resistance forces generated by the rock
material, and the working environment when the
machine operates underwater, since these affect the per-
formance of the entire system.
Frictional resistance in rock cutting. The force is also needed
to overcome the friction between cutters and the confin-
ing work face. This is not significant when radial accel-
erations are low, of the same order as the gravitational
acceleration, but for small high-speed RC tools, it could
be significant. Ignoring gravity, and assuming that the
cuttings scrape over the work face as a coherent mass,
the force needed to overcome the friction FF is
FF = mrm vu
_ t ð35Þ
where m is the rock-to-rock friction coefficient, rm is the
in situ density of the work material, ut is the tangential
velocity of cutter tip, and v_ is the volumetric rate of cut-
ting as shown in equation (49).
Hydrodynamic resistance during underwater cutting. When a
RC tool is operating under the water, churning of the
water causes additional resistance and the power loss.
When analyzing or designing for underwater work, it is
necessary to have at least an approximate estimate of the
magnitudes of these effects. This leads to an estimate of
the hydrodynamic resistance FW for each cutter tool as
1 1
Fw = CD Aru2 = CD hct wct ru2 ð36Þ
2 2
where CD is a drag coefficient of order unity, A is the
frontal area of the tool and its mount, r is the fluid den-
sity, and u is the tool speed. We have taken here a pair
of ‘‘effective’’ values for the height of tool hct and width
of tool wct, such that hctwct = A.
Following this procedure, we can write the mean
shear stress t w that is induced by hydrodynamic drag as
 
1 hct
t w = CD ru2 ð37Þ
2 S
where S is the distance between tracking cutters.
Gravity and buoyancy forces
Gravity and buoyancy forces are also termed restoring
forces. In this UTV system, we assume that the center
Vu et al. 11

of the gravity force and the center of the buoyancy

force are at the same point by positioning of buoyancy
material. Thus, the two forces can be written as

W = mg ð38Þ
BT = pgVr ð39Þ
where r is the fluid density, g is the acceleration due to
the gravity, m is the total mass of complete system, and
Vr is the volume of the RC tool.
Figure 7. Moments affecting the balance of a combined UTV
system with the RC tool.
CG: center of gravity.
Analysis of the traction of the UTV
For a given type of the vehicle running on a given type
of ground, the forward tractive thrust is usually pro- where K = (kR =ku ).
vided by the net traction of the wheels or the crawler
tracks. This net traction, which excludes the motion
resistance of the track system, is known in the field of Analysis of the moment of the RC tool (weight and
the vehicle technology as the drawbar pull Dp. It gives balance)
a measure of the vehicle’s reserve capacity to pull, push,
We neglect the additional hydrodynamic inertia forces,
or climb slopes. A dimensionless ‘‘drawbar coefficient,’’
resulting from the added masses normally considered
CT is commonly defined as the drawbar pull divided by
for accelerating submerged bodies and also do not take
the vehicle weight
into account the effect of the underwater cable in this
DP article.
CT = ð40Þ Figure 7 shows the main external forces acting on
W
the RC tool and moment arms, where H, V, Br, Wr, Bv,
On moderately firm ground surfaces (including dry Wv, and Dp are the tractive thrust, the down thrust, the
snow), CT for track-laying vehicles is typically in the buoyancy force of the RC tool, the weight of the RC
range 0.3–0.8. In the case of the UTV that carries a tool, the buoyancy force of the UTV, the weight of the
rotation RC tool, the normal force between the running UTV, and the drawbar pull, respectively.
gear and the ground depends on the vehicle gross With an RC tool on a UTV, it is important that the
weight W, the down thrust force V, and the buoyancy RC tool be mounted in such a way that the pitching
force of the overall system BT. In the simple case, the moment developed by the axle force stays within accep-
drawbar pull Dp is table limits. The RC tool is often mounted in such a
Dp = CT (W  (V + BT )) ð41Þ way that forces on it have appreciable moments about
points on the supporting system. Both the deadweight
As discussed earlier, V can be either positive or nega- of the RC tool and the cutting force have moments that
tive, but follows the convention that V is positive when need to be accounted for in the design of the carriage
the machine has to thrust downward into the work. system and the manipulating mechanism.
The amount of power represented by the thrust power For illustrative purposes, we will take moments
PH (= UH) and the losses in the running gear (includ- about the center of area of the UTV. An ordinary,
ing internal and external motion resistance) is usually unmodified tractor is likely to have its weight Wv dis-
quite small so that there is no great difficulty in supply- tributed over the running gear in such a way that the
ing adequate power to the tracks. Thus, the drawbar center of the gravity is more or less directly above the
pull is limited by the tractive efficiency of the running center of the area of the track system. The static bal-
gear, which is expressed by CT; in order to traverse a ance may be designed to make the machine slightly
RC tool, Dp must be equal to, or greater than, H nose heavy, to compensate for the small moment devel-
oped by pulling or pushing. A rotary RC tool attached
H4CT (W  (V + BT )) ð42Þ to the front or the rear of such a tractor immediately
For an up-milling RC tool mode, this leads to the disturbs the static balance, and there are further com-
condition plications when the RC tool begins to operate.
Figure 7 gives the simple diagram of the forces and
     
Ft R K d 1 the moments. For the net pitching moment to be zero,
W5 um 1  2 þK the condition is
2 d CT R CT
  1=2  #
d 2R K (Wv  Bv )X1 + (Wr  Br  V)X2  HX3 = 0 ð44Þ
 1 1 1
R d CT
When V is positive and greater than Wr, there is
ð43Þ clearly an advantage to having the distance X2 as short
12 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)

as possible. When V is negative (the RC tool pulling The total power output PT comprises the net power
itself into the work) or less than Wr, it may be more Pr, the thrust power PH and the power loss PL
convenient to eliminate its moment by having reaction
shoes or rollers that restrain the RC tool from further PT = Pr + PH + PL ð50Þ
penetration. The moment represented by the third term PT = 2pfT + UH + PL ð51Þ
of equation (44) is small if X2 is small, and the moment
In this context, PL is the power that does not con-
created by H is not likely to cause much difficulty, since
tribute directly to the cutting process. The process-
the tractors are designed to accommodate such a
specific energy Es for cutting is based on the actual
moment. The moment arm X2 should obviously be kept
power used for cutting or excavating, excluding PL
as short as possible, if only for structural reasons. The
effect of the positive V is partly offset by the RC tool PT  PL Pr + PH
weight Wr, and with the negative V, the RC tool can be Es = = ð52Þ
v_ v_
fitted with auxiliary running gear (depth limiters) to
provide local reaction against the surface. From equation (52), we obtain
2pfT + UH
Es = ð53Þ
Analysis of the energy and power of the UBd
RC tool
Energy and power considerations are very important Power density
because they directly affect machine performance. The term power density is used here to denote RC tool
power per unit area of cutting surface. For a transverse
Machine power rotation RC tool of radius R, width B, and power Pr,
the power density Q is
The energy considerations for cutting machines can be
discussed conveniently in terms of the power consumed Pr
Q= ð54Þ
in the various parts of the system. The power for any Rum B
component or subsystem can often be obtained from
where um = cos1 ½1  (d=R). Since Q varies with um ,
the product of the force and the velocity. For a single
that is, with d/R, it is also convenient to define a nom-
cutter tool at any part of its working stroke, the power
inal power density for some fixed value of um . For typi-
Pc is essentially the product of the tangential force com-
cal machines that operate with d/R \ 2, the nominal
ponent fu and the tangential velocity of cutter tip ut
power density QN can be defined for the value um = p=2
Pc = fu ut ð45Þ
2Pr
QN = ð55Þ
From equation (22), the net power Pr required for pRB
cutting can be expressed as
As QN decreases, we would obviously expect the per-
Pr = Ft ut = 2pfT ð46Þ formance of a machine to improve, assuming that
dynamics or kinematic limits are not reached, and it
The thrust power PH that is needed to traverse the may be of interest to relate the power density to the
RC tool through the work is specific energy. The process-specific energy Es for the
RC tool is its net power output divided by the volu-
PH = HU ð47Þ
metric excavation rate
where H is the tractive thrust and U is the traverse
Pr
speed. Es = ð56Þ
UdB

Specific power
Simulation
The specific energy of a cutting machine is defined here
as the energy required to cut a unit volume of the mate- We give the following simulation in order to illustrate
rial. The overall specific energy for a complete machine application of the concepts and equations. This is based
EST is based on the total power output of the machine PT on an actual engineering problem, but has been simpli-
fied so as to concentrate on the key points.
PT
EsT = ð48Þ
v_
System description
where the volumetric rate of cutting or excavating v_ is a
function of traverse velocity U, width of RC tool B and The Underwater Construction Robotics R&D Center
cutting depth d, that is (UCRC) at KIOST has been developing an UTV with
RC tool which the principal parameters for the simula-
v_ = UBd ð49Þ tion and the simulation results are listed in Table 1. As
Vu et al. 13

Table 1. Principal parameters for the simulation and simulation results..

Principal parameters for the simulation

Parameters Notation Unit Value Range

Maximum cutting depth d m 0.3 0 4 d 4 0.3

Tip radius of the cutter tool r mm 1.2 0.13 4 r 4 1.5
Maximum transverse speed U m/s 0.083 0.00178 4 U 4 0.331
Weight of the system including UTV and a RC tool W kN 294.3 2
Maximum drawbar coefficient CT 2 0.6 0.2 4 CT 4 0.6
Coefficient of the shape cutter tool K 2 1.8 14K42
Coefficient of friction for sliding or rolling of the RC tool m 2 0.1 0.05 4 m 4 0.25
against the supporting RC tool
Weight of the RC tool Wr kN 6.867 2
Weight of the UTV Wv kN 264.9 2
Width of the RC tool B m 0.5 2
RC tool radius R m 0.25 2
Diameter of the RC tool Dr m 0.5 2
Buoyancy force of the RC tool Br kN 7.182 2
Buoyancy force of the UTV Bv kN 59.566 2
Seawater density r kg/m3 1025 2
Cutter tools per revolution in each ring n 2 10 1 4 n 4 20
Rings of cutter tool across the width of the RC tool m 2 10 1 4 m 4 15
Maximum operating speed f rpm 60 0 4 f 4 190
Tool speed u m/s 1.571 04u45

Simulation results
The proportionality constants with dimensions kR 2 1292
of the force (representing tool geometry and rock properties) ku 2 781
Maximum net overall cutting force of the RC tool Ft kN 94.863
Maximum tangential component of the tool force fu kN 4.8658
Maximum radial component of the tool force fR kN 8.7558
Maximum torque of the sprocket T kN m 23.72
Maximum power density Q kW/m2 672.7
Maximum volumetric production rate v_ m3/s 0.01245
Maximum tractive thrust H kN 177.96
Maximum down thrust V kN 29.486
Maximum specific energy Pr hp 202.7
Maximum thrust power PH hp 20.1

UTV: underwater tracked vehicle; RC: rock crushing; rpm: round per minute.

shown in Table 1, where the width of the RC tool is

0.5 m, its drum RC tool diameter is 0.5 m, and its
weight is 6867 N in air without water ballast, the RC
tool is targeted to cut a 0.5 m width and 0.3 m cutting
depth. The working environment is on a ground (or
seabed) with the maximum uniaxial compressive
strength of 20 MPa, drawbar coefficient in range of
0.3–0.6, and normal friction coefficient of 0.1. Based
on a series of reports covering mechanics of various
cutting and boring machines in Mellor,13 the ranges of
the principal parameters for designing an RC tool can
be defined (Table 1). Figure 8 shows the RC tool,
where we assume the cutter tools on a wide, rigid drum
RC tool are disposed in m = 10 rings across the width
of the drum, and that there are n = 10 uniformly
spaced cutter tools in each ring. The RC tool is pushed Figure 8. The RC tool.
Source: Sandvik.12
into the material, and as it rotates while the UTV
moves forward, the cutter tools (bits) cut through the
rock material. The RC tool usually operates at its full maximum level, which depends on the dimensions of
capacity, and ideally, the tangential velocity of the cut- the RC tool, and the resistance of the rock mass. The
ter tool tip remains constant (1.571 m/s). The travel travel speed of the UTV varies in the range from 0 to
speed of the system is automatically kept at the 300 m/h.
14 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)
"   1=2  #
Steps of calculation for the design process kR R kR d 2R d
A= um  1 1 + 2
The analysis process can be summarized in the follow- ku d ku R d R
ing steps:

Step 1. Start with a given set of performance require- "     1=2 #

ments: RC tool size (width and diameter of RC tool),
rock strength, and the volumetric production rate
(Table 1).
Step 2. Provide the necessary RC tool dimensions
along with the ability to cut the given rock strength
(Table 1).
 Acquire technical specifications, such as the tooth
pattern layout on the RC tool, tool speed, and chip-
ping depth.
1. Estimate of the designed parameters of the
RC tool including m, n, kR, and(see sections
‘‘Forces on individual cutter tools,’’ and ‘‘Net
overall cutting force and tool force,’’ and equa-
tions (9)–(11) and (21)).
Step 3. Calculate the cutting forces:
 Assume a simplified structure of teeth as rows of
blades (number of cutter tracks) dependent on the
spacing between the tracking cutters (see section
‘‘Net overall cutting force and tool force,’’ and
Table 1).
 Determine the tangential force and radial force dis-
tribution of the individual cutter tools that depend
on the number of teeth engaged in the work and
penetration depth of teeth (chipping depth) (see sec-
tions ‘‘Forces on individual cutter tools,’’ and equa-
tions (9) and (10)) and then determine the
tangential force and radial force of the entire RC
tool per unit angle (see sections ‘‘Tractive thrust
and down thrust forces on the RC tool axis,’’ and
equations (29) and (30)).
 Determine the forces including the tractive thrust H,
the down thrust V, and net overall cutting force Ft
(see section ‘‘Tractive thrust and down thrust forces
on the RC tool axis,’’ and ‘‘Net overall cutting force
and tool force,’’ equations (21), (31)–(34)).
(a) Integrate the resolved incremental compo-
nents (including the tangential force and radial
force of the entire RC tool per unit angle), to
determine the tractive thrust and down thrust
(see equations (31) and (33)).
(b) Estimate net overall cutting force Ftmax (see
section ‘‘Analysis of the traction of the UTV,’’
and equation (57), where we set up CT = 0.43
because the desired transverse velocity was
quite small, that is, the transverse velocity
U = 0.083 m/s).
2(W  CT  BT  CT )
FT max = ð57Þ
A + B  CT
where
kR d R d 2R
B= 2  um + 1  1
ku R d R d
 Add the estimated hydrodynamics forces and resis-
tance force (see section ‘‘Resistance forces,’’ and
equations (35)–(37)).
Step 4. Determine the moment of the overall system,
and the structural as well as deployment actuation
forces for the RC tool to UTV.
 Determine the position at which the RC tool is
located.
(a) Design the moment of the RC tool (see section
‘‘Analysis of the moment of the RC tool,’’ and
equation (44)).
Step 5. Determine the power and energy of the overall
system.
 Determine the power and energy including the volu-
metric production rate, RC tool power, machine
power, torque of sprocket, specific energy, and
power density (see section ‘‘Analysis of the energy
and power of the RC tool,’’ and equations (45)–
(56)).
Step 6. Ensure that the current selection is adequate.
 Check the torque and moment requirements of the
system.
 Check that the spacing/penetration ratio is
reasonable.
 Ensure the structure, UTV system, and actuators
can provide the thrust forces needed.
Results and discussion
In this section, a number of numerical simulations are
performed using the derived approach to demonstrate
the application of the various equations to practical
problems of machine design or performance analysis.
This is based on an actual engineering problem but has
been simplified so as to concentrate on the key points.
The information generated from the proposed method
in this article is used to estimate important variables
such as cutter forces, overall forces (tractive thrust force
and down thrust force), the torque, and power require-
ments of the RC tool, and the angular position of RC
tool.
Figure 9(a) shows the relationship between the angu-
lar position u and cutting depth d as defined from equa-
tion (14), where the RC tool radius R is assumed of
fixed value. In the slot-milling mode, the RC tool cuts
across its complete semi-circumference. This means that
Vu et al.
Figure 9. Angular position of the RC tool, tool forces, and tractive thrust and down thrust of RC tool: (a) angular position u,
(b) the tool forces fu and fR, and (c) tractive thrust H and down thrust V (with K = 1.8).
the maximum depth equals the diameter of RC tool (or
d = 2R), or the maximum angular position u = 180°.
With a typical up-milling RC tool and we assume that
the RC is more than axle deep in the work (d/R . 1),
as is discussed in section ‘‘Terminology,’’ the RC tool is
sunk into the work to a depth less than the diameter (or
d \ 2R), we can define the ratio between cutting depth
d and radius of RC tool R in the range of 1 \ d/R \ 2
and the angular position is in the range of 90° \ u
\ 180°. From this figure, it can be seen that one RC
tool revolution is from 0° (at d/R = 0) to 180° (at d/
R = 2). The figure also shows that the angular position
u varies from zero at point of entry u = 0 to a maxi-
mum value at the point of exit um = cos1 (1  d=R).
The maximum value can occur at the maximum angular
position umax \ p=2 with d/R \ 1 or umax = p=2 with
d/R = 1, or umax \ p=2 with d/R . 1.
For the tool forces analysis, we used equations (9)
and (10) to determine the radial component force fR
and the tangential component force fu as functions of
chipping depth. Since the chipping depth ‘ varies sys-
tematically through the working sweep on a transverse
rotation machine, fu and fR are functions of angular
position. Figure 9(b) shows the relationship between
15
the tool forces of each individual cutter tool fu , fR, and
the variation of the cutting depth d at a fixed RC tool
radius R, respectively. The result shows that the radial
component of cutting force fR always increases more
rapidly than the tangential component fu , and the ratio
of the maximum radial component fR to the maximum
tangential component fR is 1.8 because the quite worn
cutter tools are used in this study. Moreover, in an up-
milling RC tool if cutting depth is greater than radius
of RC tool (d . R), fu will rise from zero at point of
entry u = 0 to a maximum at a point roughly halfway
u = p=2 through the working stroke (because the chip-
ping depth of each individual tool is proportion to
sin u at intervening positions and it reaches the maxi-
mum value ‘max at u = p=2), before decreasing back to
zero at u = cos1 (1  d=R) and then remaining zero as
shown in Figure 9(b).
Figure 9(c) shows the relationship of the RC tool
force components H and V against the ratio between d
and R as defined from equations (32) and (34). We
observed that with the RC tool only slightly touching
the workspace, that is, with d close to zero, the resis-
tance to forward motion H and the required down
thrust V would be zero because of the cutting depth
16 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)
Figure 10. The torque of the sprocket.
d = 0 m. Setting the RC tool deeper into the work
would produce increases in both H and V. As d is
increased, the tractive thrust H would increase very sig-
nificantly and reach a maximum value of H = 232 kN
at d/R = 1.9. If d is further increased, the value of H
then falls off again. The normal reaction V would not
increase very much, and when the RC tool is set to a
depth equal to about 50% of the effective radius, that
is, at d/R = 0.5, it would reach a maximum value of
V = 26 kN. If d is further increased, the value of V then
falls off again. If d is increased even more, V continues
to decrease, dropping to zero at d/R = 1.1 and then
becoming negative at greater depths.
The torque of the sprocket is the one of main impor-
tant variables for designing RC tool that describes the
operating torque input applying to the RC tool to be
able to work in a certain target working environment.
Figure 10 shows the relationship between torque of the
sprocket and cutting depth. We simulated the results
from the values in Table 1 and from equation (22). The
result above shows that while increasing the cutting
depth d, the torque of the sprocket of the RC tool
increases linearly because it is a linear function of the
cutting depth d as shown in equations (21) and (22),
and the maximum value is T = 40 kN m at the ratio
between d and R, d/R = 2.
It is important to know in advance the capacity of
the carrier vehicle so that the trenching operation can
be executed properly on certain ground/soil condition.
While power density of RC tool is used to denote the
RC tool power per unit area of cutting surface, the net
power and thruster power are the power consumed by
the RC tool for cutting and the power used to over-
come cutting resistance in the direction of advance,
respectively. In order to determine the net power,
thrust power, and power density with variation of the
depth cutting, we use equations (46), (47), and (54),
respectively. For the energy of RC tool analysis pur-
pose, Figure 11 shows the power and power density
Figure 11. The thrust power, power density, and specific
energy.
against the various cutting depth. It was observed that
the proposed system has built to trench the depth of
cutting from d = 0 m to a maximum depth d = 2R m.
The figure also shows that with the RC tool only
slightly touching the workspace, that is, with d close to
zero, all of the net power, thrust power, and power
density would be zero. Driving the RC tool deeper into
the rock material, finally it reaches at the maximum
cutting depth d = 2R are 230 kW, 525 kW/m2, and
11.5 kW, respectively.
Conclusion
In this article, we conducted analyses on the design and
mechanics of a developing UTV with a rotating RC
tool for rock excavation. We analyzed the parameters
that affect the performance including the cutting forces,
torque, and power requirements of the UTV with the
RC tool in rock conditions for designing. Also, we ana-
lyzed the parameters that affect cutting performance of
the designing RC tool, so as to provide improved RC
tool performance prediction modeling. As a study, we
derived the mathematical expression of the mechanics,
relating the forces and moments of the RC tool to the
UTV. For this, starting from an analysis on the forces
developed on individual cutter tools, when they are
mounted on a RC tool, and then we analyzed the net
overall cutting force on a complete RC tool. Through
these analyses, we present the calculation process of the
required tractive thrust and down thrust forces of the
combined UTV system with a RC tool. We present
the design scheme of the rotor carriage considering the
moment caused by the cutting system. Similarly, we
estimate the energy and the power needed to actuate the
RC tool under the water in relation to the tool charac-
teristics. The equations developed in this article might
be usefully applied for determining the design appropri-
ate data of the overall system and its performance.
Since we analyzed a UTV with underwater RC tool, the
Vu et al. 17

effect of buoyancy force on the analysis of the traction
of the UTV as well as hydrodynamic resistance and fric-
tion resistance during underwater cutting are presented.
Furthermore, we used our methods for the analysis
of a developing UTV system with the RC tool. The typ-
ical steps of the analysis process to be followed for a
combined UTV system with RC tool are presented in
this article. These typical steps of design process are
useful using for reference when designing a trencher
machine. Finally, we conducted a number of simula-
tions using the presented equations for practical prob-
lems in the design and the analysis of the RC tool.
Declaration of Conflicting Interests
The author(s) declared no potential conflicts of interest
with respect to the research, authorship, and/or publi-
cation of this article.
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Funding
Appendix 1
The author(s) disclosed receipt of the following finan-
cial support for the research, authorship, and/or publi- Notation
cation of this article: The research is a part of project a dimensionless exponents
titled ‘‘R&D center for underwater construction b dimensionless exponents
robotics,’’ South Korea (PJT200539), funded by the A frontal area of the tool and its mount
Ministry of Oceans and Fisheries (MOF), and a part of B width of RC tool
the Basic Science Research Program through the Br buoyancy force of the RC tool
National Research Foundation of Korea (2016R1 BT buoyancy force of the combined UTV
A2B4011875) funded by the Ministry of Science, ICT system with RC tool
& Future Planning. Bv buoyancy force of the UTV
CD drag coefficient of order unity
References CT drawbar coefficient
1. Muro T and O’Brien J. Terramechanics: land locomotion d cutting depth
mechanics. Abingdon: Taylor & Francis, 2004. Dp drawbar pull
2. Rubinstein D and Hitron R. A detailed multi-body Es specific energy
model for dynamic simulation of off-road tracked vehi- EST overall specific energy
cles. J Terramechanics 2004; 41: 163–173. f rotational frequency of the RC tool
3. Solis J and Longoria R. Modeling track–terrain interac- fR radial component of tool force
tion for transient robotic vehicle maneuvers. J Terrame- fR0 radial cutting force per unit angle
chanics 2008; 45: 65–78. fu tangential component of tool force
4. Hong S, Kim H and Choi J. Transient dynamic analysis fu0 tangential cutting force per unit angle
of tracked vehicles on extremely soft cohesive soil. In: FF force needed to overcome the friction
Proceedings of the 5th international society of offshore and
Ft net overall cutting force
polar engineers Pacific/Asia offshore mechanics sympo-
FW hydrodynamic resistance
sium, Daejeon, Korea, 17–20 November 2002, pp.100–
107. Mountain View, CA: International Society of Off- g acceleration due to the gravity
shore and Polar Engineers. h effective tool length
5. Morgan N and Cathie D. Tracked subsea trencher mobi- hct height of tool
lity and operation in soft clays. In: Proceedings of the H tractive thrust
17th ISOPE conference, Lisbon, 1–6 July 2007, pp.1366– kR, ku proportionality constants with dimensions
1373. Mountain View, CA: International Society of Off- of force
shore and Polar Engineers. K ratio of tool force components
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Mech Min 1972; 9: 261–270. m rings of cutter tools across the width of
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615–618.
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complete revolution of the RC tool
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distance plots. In: Proceedings of the 2nd international P machine power
18 Proc IMechE Part M: J Engineering for the Maritime Environment 00(0)

PA power for accelerating cuttings m rock-to-rock friction coefficient

PF power needed to overcome friction r fluid density
PH thrust power tw mean shear stress
PL power loss v angular velocity of the RC tool
Pr RC tool power (net power)
PT total power output of the machine Subscripts
Q power density
A accelerating
r radius of curvature of the cutter tool tip
ct cutter tool
R RC tool radius
d drawbar
s lateral tooth spacing
D drag
S distance between tracking cutters
e exit
(circumferential tooth spacing)
F friction
T RC tool cutting torque
H thrust
u tool speed
L loss
ue tool velocity at the point of exit
p pull
ut tangential velocity of the RC tool
r rock crushing
u2t =R radial acceleration
R radial component
U traverse velocity
s specific
V down thrust
ST overall specific
Vr volume of the RC tool
t torque
v_ volumetric rate of cutting or excavating
ta tangential
wct width of tool
T total
W combined UTV system with RC tool
v underwater tracked vehicle
weight
w mean
Wr weight of the RC tool
W hydrodynamic
Wv weight of the UTV
u tangential component
u angular position of the RC tool

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