Numerical Optimization of Roller Cutter Symmetrical Structural Design for Shaft Excavation in Western Jurassic Strata Through the FDEM Approach

Drilling methods have been increasingly employed for shaft excavation in coal mines in western China. However, the rock fragmentation performance of milled-tooth roller cutters remains inadequate under Jurassic strata conditions. To address this issue, a numerical orthogonal simulation study based on the Finite-Discrete Element Method (FDEM) was conducted. Cutter tooth edge geometry, cutter diameter, cone angle, and penetration depth were considered as four factors at three levels. The effects of these factors on average force, specific energy, damage factor, and proportion of shear cracks were investigated. The efficiency coefficient method was then applied to identify the optimal cutter, and the 8# roller cutter was determined to be the most effective. The results indicated that cutter tooth edge geometry had the most significant influence on average force and specific energy, whereas penetration depth primarily affected the damage factor and proportion of shear cracks. Compared with the prototype cutter, the 8# cutter, characterized by a 370 mm large cone-end diameter, a 3° cone angle, and V-edged teeth, exhibited superior rock fragmentation efficiency, achieving a maximum improvement of 31%. These results provide a theoretical basis for the structural optimization of cutters used in shaft drilling in coal mines in western China.