Introducing a new rock abrasivity index using a scaled down disc cutter

Rock abrasivity influences wear of cutting tools and consequently, performance of mechanized tunneling machines. Several methods have been proposed to evaluate rock abrasivity in recent decades, each one has its own advantages. In this paper, a new method is introduced to estimate wear of disc cutters based on rock cutting tests using scaled down discs (i.e. 54 and 72 ​mm diameter). The discs are made of H13 steel, which is a common steel type in producing real-scale discs, with hardness of 32 and 54 HRC. The small-scale linear rock cutting machine and a new abrasion test apparatus, namely University of Tehran abrasivity test machine, are utilized to perform the tests. Tip width of the worn discs is monitored and presented as the function of the accumulated test run to classify the rock abrasion. Abrasivity tests show that by increasing the uniaxial compressive strength (UCS) of the rock samples, wear rate is doubled gradually that reveals the sensitivity of the test procedure to the main parameters affecting the abrasivity of hard rocks. For the rocks with the highest UCS, the normal wear stops after performing 5 to 10 rounds of the tests, and then, deformation of the disc tip is detectable. Two abrasivity indices are defined based on the abrasivity tests results and their correlations with Cerchar Abrasivity Index (CAI) and UCS are established. Comparison of the established correlations in this study with previous investigations demonstrates the sensitivity of the indices to the parameters affecting wear of the disc cutters and repeatability of the outputs obtained from abrasivity tests using scaled down discs. Findings of this study can be used to enhance the accuracy of rock abrasivity classifications.