Simulation‐Based Performance Analysis of Roadheader Picks Considering Environmental Characteristics and Motion Trajectories

ABSTRACT

Boom‐type roadheaders face a trade‐off between cutting efficiency and component degradation, requiring precise performance evaluation of picks. To address high tunneling experiment costs and limitations of conventional simulations in rock modeling and motion reproduction, a performance analysis framework is developed via co‐simulation based on Multibody Dynamics and the Discrete Element Method. This framework integrates three methodological contributions: (1) a reusable parametric simulation platform is constructed to resolve the complex “environment‐motion” coupling, realizing a parameter mapping method that accurately associates macroscopic rock properties and actual motion trajectories with simulation boundary conditions; (2) oriented toward the cost‐effective cutting mode, this study evaluates the performance of picks under the typical “S‐shaped” path, specifically assessing the rock‐breaking rate, load strength, and wear rate; (3) a component decoupling strategy and motion path segmentation are implemented to systematically analyze 25 distinct performance indicators of picks. Consequently, utilizing the enhanced Latin Hypercube Sampling (LHS) and Partial Dependence Plots (PDP) to conduct batch simulations, this study rigorously investigates the performance evolution laws, degradation mechanisms, and key influencing factors across different cutting phases. This work provides a rigorous workflow for tunneling equipment optimization, especially for the development of high‐fidelity digital twins.