Discrete element method analysis of cutter forces and cutter tooth wear in cutter suction dredgers

Abstract. During dredging operations, cutter teeth undergo severe mechanical wear due to continuous rock impact and abrasion, significantly reducing operational efficiency and equipment lifespan. This study investigates force distribution and wear mechanisms using a three-dimensional discrete element model developed in EDEM (commercial discrete element method software developed by DEM Solutions, UK), incorporating a bonded-particle rock representation to simulate excavation under varying operational parameters. Simulation results reveal distinct mechanical patterns: cutter teeth located at the hub side experience substantially higher stress concentrations, with wear accumulation approximately 30 times greater than that on the large-ring side. Material loss is most pronounced on the upper surfaces of the teeth. Cutting force increases nonlinearly with traverse speed and decreases with rotational speed, while variations in cutting angle have a minimal effect within the tested range. Systematic analysis identifies the optimal operational regime as a traverse speed of 0.2 m s−1 combined with a rotational speed of 20 rpm, corresponding to the lowest specific energy consumption. These findings provide a theoretical basis for improving dredger performance through targeted reinforcement of key components, optimization of operational parameters, and predictive maintenance based on quantified wear patterns.