Development of a methodology for calculating the working process of the rotary working body of machines for earthworks and road works

The object of this research is the working process of high-speed separation of soil mass elements by the cutting elements of a rotor. The existing problem is that soil cutting by the rotor occurs during the translational movement of the base machine. This creates a complex trajectory of the cutting edge and leads to continuous changes in chip thickness. Considering the trajectory of the cutting edges and the function of chip thickness variation allows for a more accurate assessment of the energy characteristics of the rotor drive. Key parameters, such as the torque on the drive shaft, drive power, and energy consumption, were analyzed as functions of the working body's geometry, rotational speed, base machine velocity, and soil properties. The obtained mathematical models account for the actual trajectories of the cutting elements and changes in soil cutting thickness. Additionally, the interaction conditions with the surrounding environment and the physical and mechanical properties of the soil were considered. A methodology for engineering calculation and optimization of the rotary working body’s parameters was developed. It considers the rotor’s design, size, interaction conditions, and environmental factors. Analysis of the working process of a rotary working body with specified parameters and soil properties led to the following conclusions: – The power consumption for the drive and the energy intensity of the process in direct and reverse soil cutting are practically equal. The differences do not exceed 5 %. – In reverse operation, the average horizontal component of soil cutting resistance increases by 1.15–1.25 times compared to direct cutting. However, the resistance force vector is directed toward the working body's movement, reducing the required traction force of the base machine. – The average value of the vertical component of cutting resistance in reverse operation is 2.0–2.5 times lower than in direct cutting. This reduces the effort required to deepen the working body or adjust the soil development depth. This study will be useful for machine-building enterprises specializing in the design and manufacture of earthmoving and road construction machines, particularly those with an active rotary working body.