Optimization simulation and crushing experiment of anti-impact energy absorption component of hydraulic support column

Abstract

Hydraulic support, being the primary supporting equipment in coal mining operations, is frequently subjected to rock burst pressure. Hence, the anti-impact energy absorption components play a pivotal role in safeguarding the hydraulic support system. Based on the research foundation established by our anti-impact components research group, a detailed investigation on the parameters of energy-absorbing components was conducted for achieving an enhanced initial peak force and absorption energy, as well as reducing the dispersion of reaction forces. Subsequently, the ABAQUS finite element software was employed for modeling and simulating the crushing impact behavior of these energy-absorbing components. The energy absorption performance and buckling deformation characteristics of the energy absorption component were determined, and the optimal size was experimentally validated for its energy absorption performance. By comparing the predicted average support force data of the energy-absorbing member with the finite element simulation results, it was observed that the error is below 15%. Furthermore, for the optimal size member, the prediction error of the average support force model is −3.40%, thus confirming a higher level of accuracy in predicting data for the energy-absorbing members. A test platform was constructed to evaluate the crushing behavior of energy-absorbing components. The experiment involved conducting axial loading crushing tests on the custom-designed components under quasi-static conditions, with five different loading speeds selected. The experimental results demonstrate that the fluctuation of support reaction remains consistent across axial crushing experiments conducted at different loading speeds. The maximum peak value of initial support reaction is 2 253.52 kN, with a standard deviation of 206.23 kN. The minimum peak value of the initial support reaction is recorded as 2 096.26 kN, with a standard deviation of 189.83 kN. The average value for the initial support reaction peak is determined to be 2 149.32 kN, accompanied by an average standard deviation of 196.77 kN. The relative errors of the initial support reaction peak and standard deviation, compared to the finite element simulation data, are 5.6% and 11.07%, respectively. The energy absorption performance of the optimally sized energy-absorbing component was analyzed using three methods: a prediction model, finite element simulation, and crushing experiments. The average support reaction force obtained from the prediction model method is 1 879.7 kN, while that from the finite element simulation method is 1 945.9 kN, and that from the crushing experiment method is 1 919.8 kN. The prediction model exhibits an error rate of 3.41%, while the crushing experiment demonstrates a deviation of −1.3%. The reliability and feasibility of the analysis method for the energy-absorbing components are substantiated through the data verification results from these three approaches.

Keywords

• hydraulic pressure support
• energy absorbing member
• component processing
• optimal size
• crushing test