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 
Abstract
During automatic and intelligent cutting at the coal mining face, complex geological conditions
(fold structure, fault structure and magmatic intrusion) easily cause distinct occurrence
conditions of coal rock seams (gangue, inclusion, or fault in the coal and rock), which induces
different coal-rock cutting performances of shearer picks. Therefore, the objective of the present
study is to review the selected solutions on the evaluation of coal-rock cutting performances of
shearer picks under complex geological conditions. Occurrence conditions of coal rock seams
were classified according to different criteria. Mechanical coal-rock breakage of coal rock by
shearer picks were introduced. Shearer pick forces during coal-rock cutting (load spectrums of
the pick and the mechanical model of the pick force) and coal-rock cutting mechanism (coal-rock
cutting process by the pick and pick failure mechanisms) were discussed. The service safety
evaluation of the pick based on wear and fatigue (pick wear, quantitative evaluation of service
safety, and methods to improve the service safety) was presented. Finally, research prospects
were outlined to propose the future research focus of shearer picks under complex geological
conditions, such as the adaptive cutting of shearers, the fusion detection method of coal-rock
interface by automatic shearers, the effects of geological conditions on coal-rock cutting
mechanisms, the selection of systems suitable for different geological conditions, and shearer
pick reliability evaluation. Results of this study are of great significance in understanding failure
modes and the cutting mechanisms of shearer picks, quantitatively evaluating pick safety,
promoting the automatic and intelligent cutting of coal rock seams, and thereby improving the
production efficiency of shearers.
Keywords: shear (/search?q=shear); picks (/search?q=picks); geological conditions
(/search?q=geological+conditions); coal-rock cutting (/search?q=coal-rock+cutting)
https://www.mdpi.com/2076-3417/12/23/12371 4/73
1. Introduction
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The shearer is an important piece of equipment at the fully mechanized coal mining face
(Figure 1). The pick is the core component of the cutting unit as the key device of the shearer
[1,2]. During automatic and intelligent cutting at the coal mining face, the complex geological
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conditions, such as the fold structure, fault structure and magmatic intrusion, induce distinct
occurrence conditions of coal rock seams (gangue, inclusion, or fault in the coal and rock), and
the difficulty in the identification of complex coal-rock interfaces at the coal mining face [3,4,5].
Complex occurrence conditions, shearer vibration, rotary cutting of the helix drum and uneven
track will cause the wear deterioration and even fracture of the pick when cutting the coal wall
[6,7], which greatly affects the safety and reliability of the pick, service life of the drum and
production
 efficiency of the shearer. Therefore, it is essential to master occurrence conditions of

coal rock seams, mechanical coal-rock breakage by shearer picks, shearer pick forces during
cutting, the coal-rock cutting mechanism and service safety evaluation of the shearer pick.
However, the correlations between complex geological conditions and wear deterioration/safety
and reliability evaluation of shearer picks have not been reported yet. The reviews on the cutting
loads, cutting mechanisms, quantitative evaluation of wear deterioration and service safety
evaluation of shearer picks are of great significance for establishing the wear deterioration
evaluation system of shearer picks and obtaining the influencing factors of wear deterioration of
shearer picks. Meanwhile, research results can promote automatic and intelligent cutting of coal
rock seams, reduce the equipment fault rate and improve production efficiency of the shearer.
However, this article is a comprehensive review of selected solutions on the evaluation of coal-
rock cutting performances of shearer picks under complex geological conditions. The results can
be applied in cases of the complex geological conditions in countries and regions concerned in
the present study.
Figure 1. The fully mechanized coal mining face.

The aim of the present study is to present the evaluation of coal-rock cutting performances
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of shearer picks under complex geological conditions, nevertheless, due to the volume of the
article, only the most important solutions published in recent years are presented. Section 2
shows the occurrence conditions of coal rock seams. Mechanical coal-rock breakage of coal searchmenu
rock by shearer picks is introduced in Section 3. In Section 4, the research progress on shearer
pick forces during coal-rock cutting is presented. Section 5 exhibits the coal-rock cutting
mechanism. The service safety evaluation of the pick based on wear and fatigue is reviewed in
Section 6. Finally, the research prospect is proposed in Section 7.
2. Occurrence Conditions of Coal Rock Seams

 
Occurrence conditions of coal rock seams at the coal mining face are affected by geological
structure conditions. In the case of folded structures, coal rock seams are compressed due to
plastic deformation of strata and exhibit the wavy bending, which results in the coal seam
thickness change locally. As the geological condition is a fault structure, the fault of a coal rock
seam induces the discontinuity of mining operation. However, the geological condition of magma
intrusion reduces the thickness of the coal seam and increases its hardness, which hinders the
continuity of shearer operation [8].
In general, occurrence conditions of coal rock seams are composed of whole coal and
whole rock (through the fault) as well as coal and rock mixtures (coal and roof, coal and floor,
coal and gangue, coal and inclusions) [9]. The roof and floor strata are located above and below
the coal seam, respectively; complex coal seams show at least 1–2 layers of stable gangue
strata, and several layers at most (Figure 2) [10]. In China, there are lots of coal bases and
mining areas which exhibit distinct geological occurrence conditions of coal seams as shown in
Table 1. According to coal seam thickness, the coal seam can be divided into thin coal seam
(<1.3 m), medium thick coal seam (1.3–3.5 m) and thick coal seam (>3.5 m). According to the
standard GB/T 18023-2000 in China, the coal is macroscopically divided into bright coal
(vitreous and bright coal > 80% and presence of metallic or metal-like luster), semi-bright coal
(vitreous and bright coal 50–80% and presence of glass luster), semi-dark coal (vitreous and
bright coal 20–50% and presence of dull luster) and dull coal (vitreous and bright coal < 20%
and presence of silk luster). However, there are lots of classification methods of coal lithotype
according to different criteria (Table 2). Li et al. [11] revealed that hard dirt bands are mostly
distributed about 0.34 m away from the roof with a thickness of 0~0.4 m, of which 71% exhibits
the thickness of 0~0.2 m and 21% presents the thickness of 0.2~0.4 m. They are distributed
unevenly in layers. Generally, areas with hard dirt bands smaller than 0.2 m can be directly
mined by the improved powerful drum-reinforced pick shearer. Areas with hard dirt bands thicker
than 0.2 m need to be blasted. Krivosheev and Koval [12] employed the instrument for recording
acoustic signals on tape and their subsequent analysis, to obtain a “map” of seam inclusions.
Ordin et al. [13] developed the model of a coal seam with distributed geological and
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geomechanical characteristics using inverse distance weighting, and found the hyperbolic
dependences of the drum shearer advance speed and capacity on the coal seam thickness.
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 
Figure 2. Geological occurrence conditions of coal rock.
Table 1. Geological occurrence conditions of coal seams at different coal bases and
mining areas.
Table 2. Classification of coal lithotype.
3. Mechanical Coal-Rock Breakage of Coal Rock by Shearer Picks

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The mechanical coal-rock breakage indicates the direct breakage of coal rock by shearer
picks [26]. The picks are installed in pick holders, furnished on the cutting head’s lateral surface,
and together form a system of picks. The rotary mounting of picks in the holders enables their
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stochastic rotation and symmetrical wear [27,28,29]. If certain conditions related to cutting
angles are not obtained, the picks are blocked in the holders, and their wear is asymmetrical
[30,31,32,33,34]. During the selection of design parameters of the picks and holders, we have to
consider geometrical and kinematic parameters of cutterhead and cutting machine [30].
Meanwhile, the mining and geological conditions must be considered, particularly the mineral’s
properties (cutting resistance, abrasivity) [35,36,37,38,39]. In order to ensure the premised
cutting
 efficiency and costs, Krauze et al. [31] thought that conical picks should be used. Conical

picks are used in cutting heads due to their excellent durability, greater than radial or tangent
picks. The pick body is a solid of revolution consisting of working and handle parts [29,40]. The
working part is equipped with a WC-Co insert, i.e., a pick tip [41,42,43,44,45]. The quality of
conical picks is related to their construction (cutting angles, dimensions), material parameters of
the pick body (chemical composition, hardness, microstructure, steel grade), and pick tip
(dimensions, HV30 hardness, density, chemical composition-determination of the mass fraction
of carbide phase (%WC), matrix (%Co) and WC grain size).
Different mechanical coal-rock breakage equipment presents distinct pick types, layout
modes and output powers. Bakhtavar [46] determined the optimum drum shearer for Tabas mine
using decision making process. Ivanov and Ivanova [47] thought that variations in the level of
seismo-acoustic activity of the seam reflected variations in the state of stress of the seam close
to the face. From the comparison of the mechanical coal-rock breakage methods of Hob,
diamond core drilling, drag bit and impact grinding [48], it is clearly seen that the impact grinding
method exhibits good coal-rock breakage properties. As the drum shearer pick directly acts on
the coal-rock, it presents a small contact deformation area at first, then the crack initiation at the
stress concentration region below the pick occurs, afterwards the unstable crack propagation of
the main crack, and finally the formation of falling coal-rock debris [49,50]. In order to explore the
mechanical coal-rock breakage mechanism, previous researchers have proposed theoretical
cutting models [51,52,53,54] and finite element models. Meanwhile, discrete element models of
pick cutting coal rock have been established to investigate the evolution of pick force versus
cutting depth, chip formation at the leading edge of the pick, and crack initiation around the pick
[55,56,57]. Besides, Balci et al. [58] have established the full-size single-pick coal-rock cutting
machine at the Istanbul University. Bakar and Gertsch [59] have established the linear coal-rock
cutting machine at the University of Missouri. Li [32] from China University of Mining and
Technology have established the full-size single-pick coal-rock cutting machine. Detailed
illustrations of progress on the pick cutting coal rock can be found in Table 3.
Table 3.(/)Research progress on the pick cutting coal-rock.
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4. Shearer Pick Forces during Coal-Rock Cutting
4.1. Load Spectrums of the Pick
 When the shearer drum cuts the roof and floor, the occurrence of coal rock seam is directly 
related to the magnitude, direction and action location of the drum load. The cutting force will
increase suddenly when the drum cuts the roof, floor or dirt band. When analyzing the drum
load, the cutting direction of the pick presents a certain angle with the bedding of coal rock,
which changes with the rotation. The position of the dirt band and its influence degree are
considered, that is, the angle between the cutting force direction and the bedding varies with the
position of the dirt band. Therefore, load spectrums of the drum and pick can demonstrate the
cutting state and accurately identify the state of cutting coal rock, i.e., cutting the roof or the floor.
Quantitative evaluations of cutting performances under different geological conditions and
distinct cutting conditions are of practical significances for autonomous control, optimizations of
cutting trajectory and working parameters, and improvement of productivity and work safety. Cui
[75] focused on the quantitative descriptions of different geological and cutting conditions, and
established the complementary relationships between geological conditions/cutting conditions
and cutting performance/sensor sensing parameters, which improved the accuracy and reliability
of prediction and correction. He described the cutting load and direction of coal rock in cases of
the drum cutting different roof and floor, dirt band and bedding states, through the coal-rock
identification associated load characteristic model. He also proposed the load magnitude and
direction characteristics, and dynamically monitored the difference of vibration and noise under
different coal-rock occurrence conditions.
When the shearer drum cuts the roof and floor, the occurrence states of coal-rock strata are
directly related to the amplitude, direction and action point of the drum load. The cutting pressure
will increase suddenly when the drum cuts the roof, floor or dirt band. When analyzing the drum
load characteristics, the pick cutting direction presents a certain angle with the bedding and
changes continuously with the rotation. Considering the locations of dirt band and its influence
degree, the angle between cutting force direction and the bedding varies with the dirt band
location. Therefore, the exploration of load amplitude frequency characteristics of the drum
indicates that we can judge the cutting state and accurately identify the coal-rock cutting state
from the perspective of load spectrum, i.e., cutting of the roof or the floor. The quantitative
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evaluation of cutting performance in cases of different geological conditions and cutting
conditions is of practical significance for autonomous control, optimizations of cutting trajectory
and working parameters, and improvement of productivity and work safety. Cui [75] focused on searchmenu
the quantitative description of different geological and cutting conditions, established the
complementary relationship between geological conditions/cutting conditions and cutting
performance/sensor sensing parameters, and improved the accuracy and reliability of prediction
and correction. He employed the coal-rock identification associated load characteristic model to
describe the cutting load amplitude and direction of coal rock in cases of the drum cutting
different roof and floor as well as cutting distinct dirt band and bedding joint states. Meanwhile,
he monitored the differences in the vibration and noise under different coal-rock occurrence
 
conditions. Luo [76] believed that the existing dynamic analysis of the shearer drum assumed
the coal seam homogeneity, but did not consider the discontinuous characteristics of the coal
seam at coal-rock interface and its interaction with the pick and drum. Especially, mechanical
mutation behaviors and stress distribution states have not been investigated in cases of the
discontinuous impact and friction between the pick and the coal seam. When the pick and drum
are subjected to more severe impact and friction while cutting the coal seam at the coal-rock
interface, it exhibits significant discontinuity. That makes it difficult to effectively control and
predict the motion law and dynamic behavior of the drum, and to ensure the reliability of the
shearer [77,78,79,80,81]. Xuan et al. [82] proposed the possibilities of increasing the efficiency
of separating coal from the massif by improving the pick alignment schemes of shearer cutting
drums. Given the existing structural limitations of the radial extension of the picks and the
thickness of the cuts, an increase in efficiency was achieved by using combined series-group
schemes for arranging picks, including energy-efficient cutting, paired and group with a larger
cross-sectional area of the cuts and, therefore, with a larger particle size of the separated coal
fragments, reducing dust yield and specific energy consumption.
During the coal-rock cutting, especially the cutting of semi-coal, rock and hard rock, non-
uniformities of the physical and mechanical properties of coal rock induce the random vibration
load of the shearer pick [83,84]. In addition, a great deal of vibration (vibrations of motor and
traction transmission gearbox [85], vibration due to unevenness of mining face floor [86] and
impacts (meshing impact between pin row and pin teeth of the shearer traction wheel [87],
impacts due to changing meshing stiffness and manufacture error of transmission gear) is
transmitted to the pick, which accelerates the random vibration of the pick. Meanwhile, the
random vibration of the shearer pick is affected by structural parameters, kinematic parameters
and other factors as shown in Table 4.
Table 4. Influence factors of shearer pick vibration.
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In order to quantitatively demonstrate random vibration characteristics of the pick during
coal-rock cutting, it is of great significance to obtain the load spectrum of the pick. Up to now,
lots of researchers have investigated the load spectrums of shear picks through theoretical
analyses, field tests (Table 5) and computer simulations. During theoretical analyses of shearer
pick force, Soviet scholars in the 1960s calculated the cutting resistance of the wedge pick
based on rock mechanics. Nishimatsu [60] obtained the formula derivation of cutting resistance
 
and normal force. Evans [91] derived the formula for pick cutting force. Liu [92] calculated the
cutting resistance based on fractal theory. Li [77] established the mathematical model of drum
cutting resistance based on single pick cutting resistance. Zhang [93] calculated the cutting
resistance based on the reconstruction algorithm. Zhang [94] calculated the cutting force based
on dynamics theory. Ren [95] obtained the ranges of cutting force based on the Taylor formula
and Tikhonov regularization. Considering computer simulation methods of shearer pick force,
there are the finite element method [96,97], discrete element method [62,98,99] and Matlab
simulation method [100,101]. In the finite element method, the finite element model of coal seam
cutting by shearer is established using Ansys/LS-DYNA. The forces are exerted on the drum and
picks during cutting, and the load spectrums of the picks are obtained. Meanwhile, the effects of
the structural parameters of the shearer cutting unit, kinematic parameters of the shearer, and
shearer cutting condition on the load spectrums are investigated, respectively. In the discrete
element method, EDEM software is employed to establish the discrete element model of the
drum and coal rock through the settings of the mechanical parameters of particles and contact
parameters between drum and coal rock, which can induce pick forces during cutting and load
spectrum of the pick. In the Matlab simulation, the input is the pick structure, kinematic
parameters and coal-rock characteristics, and the simulation angle and step size are
determined. Afterwards, the loop variables of the rotation angle and pick number are set to
calculate the pick position and pick force. When the pick number is larger than the total pick
number and rotation angle larger than 360°, the pick and drum load spectrums are the output.
Table 5. Field tests of shearer pick forces.
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Typical load spectrums of the pick during coal rock mining of thin coal seams under different
working conditions are investigated [107,108,109]. The pick force shows the large impact as the
shear drum cuts into the coal wall; the pick forces during coal-rock cutting change periodically,
and pick forces along three directions exhibit different evolutions. In cases of different coal-rock
types, the overall pick force during coal rock cutting decreases in the order of mudstone, hard
coal and soft coal [108,109]. In coal seams with dirt bands, the pick force exhibits the largest
 
value at the middle locations of coal seam. Meanwhile, the thickness of dirt bands greatly affects
the ranges of vibration time and vibration amplitude. Zakharov et al. [110] thought that the
parameters of the cutters and their spatial orientation relative to the end of the blade of the
screw executive body had a significant impact on the power and energy performance of coal-
mining combines. They have identified the extent to which the spatial orientation of the cutter
affects the power and energy parameters of the cutting process. It was found that small values of
the angle of inclination of the cutter were optimum for the cutting forces, and the lateral
component of the load on the cutter decreased with increasing angle of inclination. Boiko [111]
compared results of theoretical investigations into the external forces acting on the cutter drum
of a shearer with results obtained using strain gauge measurements taken on the cutter picks
using a reduced-scale surface test rig. He found external forces to be random in nature and to
have similar properties to those of white noise, which did not contradict the results of strain
gauge measurements taken underground.
4.2. Mechanical Model of the Pick Force
During the coal rock cutting, the pick force directly affects the pick safety and reliability.
Previous researchers [112,113,114,115] have obtained the forces of any pick along distinct
directions at the working face. Evans [91] has derived the formulas for the estimation of cutting
forces based on the uniaxial compressive strength and shear properties of the rock. Rostami et
al. [116] introduced a prediction model of the cutting forces of the pick. Standard cutting test
procedures were developed by Roxborough and Phillips [117] to measure cutting forces of the
pick when cutting various rock samples. The trends in cutting forces, breakout angles and cutting
areas, have been investigated by Dogruoz and Bolukbasi [118]. As shown in previous studies
[119,120,121], the cutting speed did not affect pick forces, and no significant relationship was
observed between normal force and skew angle. Copur et al. [120] revealed that the cutting
pattern significantly affected pick forces and cutting efficiency. Park et al. [122] reported that the
pick cutting forces in the positive skew angle were always lower than those in the negative skew
angle. Hurt [123] performed rotary cutting tests on sandstone specimens with different skew
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angles of a pick at a 45° attack angle, and they found that the skew angle of up to +30° had no
significant effect on the cutting force. Kim et al. [121] explored the effect of the skew angle on the
cutting force of the pick through a series of linear cutting tests, and they observed no general searchmenu
tendency in the normal and cutting forces of the pick. Choi et al. [124] conducted the full-scale
linear cutting tests on mortar specimens with 0° and +6° skew angles at a 55° attack angle, and
indicated that a +6° skew angle was favorable owing to less fluctuations in the cutter forces at
different penetration depths. Dogruoz et al. [125] conducted full-scale laboratory cutting tests to
obtain the cutting forces. In addition, they measured mechanical and physical properties of rock
samples for assessment of the variation of specific energy as a function of rock properties. Li et
al. [126] analyzed the stress conditions of the pick when the spiral drum was cutting coal rock
 
with different occurrence, and revealed the reasons for wear of the pick at the outer edge of the
end plate. Zhao et al. [127] believed that when the coal seam contained inclusions, the load on
the drum was not only affected by the distribution, content, physical and mechanical properties
of the inclusions, but also affected by the action form of the pick and the inclusion, and the
number of picks cutting the inclusion at the same time. Skipochka et al. [128] analyzed the
correlation between the “cutting resistance” parameter and the ultimate strength of rocks.
Meanwhile, they proposed the three force components within a cutter when measuring the coal
cutting resistance. Finally, the dependence of coal cutting resistance on the cutting depth was
presented.
5. The Coal-Rock Cutting Mechanism

5.1. Coal-Rock Cutting Process by the Pick
During the coal-rock cutting process of the shearer pick, the pick impacts the coal rock with
the speed v which causes high contact stress at a small contact area [129,130,131]. When the
contact stress reaches the limit value, the coal rock shows the partial breakage and thus the
induced compact core of coal powder. As the cutting process continues, the compact core of
coal powder is discharged along the cone surface of pick body at a high speed, causing the
expansions of coal breakage and compact core areas. The coal powder in the compact core
accumulates the extrusion-induced energy, and the pressure continues to act on the compact
core. As the compact core expands to the contact point D, the coal rock shows small pieces
spalling. The coal powder in region II is spewed out at a high speed due to strong compression,
and presents strong friction with the pick cone surface. The accumulation region I at the pick tip
moves with the pick and shows the wedging effect on the coal rock. As the pick move to point B,
the compact core, under enough compressive stress, induces shear cracks in the coal-rock.
When the cracks expand to the coal surface, the region BCD of the coal rock spalls. The coal
rock, as a material with high brittleness, mainly presents three cracks, i.e., the open crack,
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sliding crack and tearing crack. However, the open crack plays a dominate role during coal rock
breakage by the pick.
It is important to evaluate the cutting performance of pick to determine a machine’s capacity searchmenu
and operational parameters. The cutting performance of a pick depends on various parameters,
such as the geometry (i.e., cutter type, cutter dimensions, cutter tip angle, and shape), cutting
conditions, such as cut spacing, penetration depth, cutting angles, cutting pattern, cutting speed,
and the mechanical properties of the rocks. Many studies have been conducted to establish the
relationship between the cutting performance of various machines and rock properties
[132,133,134,135,136,137,138]. Park et al. [122] conducted a series of cutting tests to explore
the effect of the skew angle of a point-attack pick on the cutting performance. They found that
 
the positive skew angle was preferred with around +10° being optimal for the selected pick cutter
in terms of cutting efficiency and structural stability. Dogruoz et al. [125] investigated the cutting
process of low- to medium-strength rocks. McFeat-Smith [139] studied the relationship between
specific energy and rock properties, and proposed estimation formulas for specific energy based
on rock properties. Fowell et al. [133,140] have set forth the standard test setting with the cutting
depth of 5 mm. Meanwhile, the laboratory specific energy has been calculated by SE = Fc/Q
[58,133]. In the equation, SE is the laboratory specific energy, MJ/m3, Fc is the cutting force, kN,
and Q is the yield per unit length of cut, m3/km.
When the shearer drum cuts a coal seam with dirt bands, the cutting object has changed
from simple coal to a coal rock mixture. Therefore, the coal-rock interface affects the cutting
performance of the shearer to a certain extent. When encountering gangue and hard inclusion
coal seams, caving mining or blasting mining is usually employed. However, this mining method
easily presents a low coal recovery rate and roof fall, which thereby affects the normal
production [17,18]. Attributed to the large difference between the strengths of various rocks,
some coalfield roofs are difficult to collapse, while others are very easy to collapse. During
mining of thin and extremely thin coal seams, the shearer can easily cut the top and rub the
bottom; the strength of the roof and floor strata affects the cutting performance of the shearer
[141]. Tiryaki et al. [142,143] studied the relationship between the specific energy consumption
of the pick and coal rock characteristics under the condition of linear cutting. They pointed out
that the specific energy consumption was significantly affected by the viscosity coefficient,
effective porosity, and pore volume of the coal rock materials. Meanwhile, they proposed that the
Poisson’s ratio, tensile strength and hardness exhibit a linear relationship with the specific
energy consumption of the pick.
5.2. Pick Failure Mechanisms
Although the ability of existing shearer drums to cut hard coal has been improved, most
shearer drums cannot cut rocks. Meanwhile, the ability to cut thin coal seams, small faults and
coal seams with dirt bands is still insufficient. The shearer drums cannot work stably in coal
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seams with faults and sandstone bands [144,145]. Especially when cutting the coal seam at the
coal-rock interface, the pick will suffer from excessive wear and fatigue failure due to the long-
term large impact load, resulting in broken and missing teeth. That not only reduces cutting searchmenu
performance, but also brings harm to the normal operation of the cutter.
The cutting picks on the shearer operate in a complex and stressful environment, i.e., the
rotation and advancement rate from the machine side as well as geomechanical conditions of
the coal seam. They transfer the energy from the shearer to the coal body, thus causing stress
concentration in the rock and ultimately leading to chip formation and coal fragmentation.
Therefore, the failure of the picks results in the extraction stoppage, and thereby causes the
extra operational costs and production loss [74,146,147,148]. In addition, failed picks may pose
 
an increased risk to personnel and production if not replaced in time, for example, causing
frictional ignition in underground coal mining production [149]. Dewangan et al. [44] thought a
number of parameters, such as pick geometry, pick body material, mounting configuration, depth
of cut and rock properties, influence the pick performance.
During coal rock cutting, the main failure modes of the shearer pick are pick wear, alloy
head shedding, pick body bending and pick body fracture. It is found that the pick wear accounts
for 45–50% of pick failure [94,150,151]. Pick wear mechanisms are abrasive wear, fatigue wear
and corrosion wear [152], of which abrasive wear dominates. The generally used pick material is
alloy steel (Table 6) [153,154,155]. In order to obtain a high wear-resistant pick material, the
carburizing process is employed [80]. In fact, the pick wear degree is affected by occurrence
conditions of coal rock seams, pick layout (installation angle, pick number, et al.), pick structural
parameters (diameter, tip angle and cone angle) and the kinematic parameters of the shearer.
Another important factor affecting the pick service life is pick body fracture, which involves the
crack initiation, propagation and final rupture [152]. However, the reasons for pick fracture may
be residual stress-induced pick defects during manufacturing [156], crack initiation and
propagation due to instantaneous pick force exceeding the ultimate strength of the pick material
[157,158,159,160,161], and the improper operation by the shearer operator [158]. In addition,
the premature failure of the pick will be accelerated due to a mismatch between pick type and
coal rock type, high dust concentration at the working face [162,163] and a wet corrosive
medium [164]. Further, Eshaghian et al. [165] investigated failures of coal shearer picks in the
Parvadeh coal mine in Iran, as well as the main mechanisms and causes for pick failures. The
reliability of picks is critical to the productivity of the shearer [166]. Eshaghian et al., believed that
pick body wear, breakage of the pick tip, slimming of pick body, and separation and removal of
the pick tip, are the most frequent failures and wear modes of studied picks.
Table 6. Commonly used pick materials.
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In order to improve the cutting performance and reduce wear failure of the pick, we should
pay more attention to the selection of structural parameters and layout of the pick. Parshyna and
Parshyn [167] proposed the relationship between the manufacturing system stiffness, and the
machining accuracy and quality, and developed a system of mathematical models. Meanwhile,
large coal block spalling and energy consumption during coal rock cutting should be fully
considered [88,168]. During the design of the drum, we should arrange as few picks as possible,
 
while too few picks will induce larger pick force and intensified wear. According to the layout of
the picks, the commonly used layouts of the end plate picks of the drum are Y type, -type and S
type layouts [1,169]. Therefore, the number, layout and installation angle of end plate picks
should be determined according to actual working conditions, in order to improve the mechanical
characteristics and prolong the service lives of the picks [170]. In cases of harsh cutting
conditions, we should increase the number of end plate picks [168] and mount inclined picks to
avoid side wear of the end plate [171]. According to the layout of picks on the drum, the optimal
pick line distance is related to the coal-rock type, shearer operation parameters and pick
structural parameters [161,172]. Too large a pick line distance causes increased pick force and
accelerated pick wear, while too small a pick line distance reduces the cutting efficiency of the
shearer [173,174]. Kumar et al. [175] proposed that reducing the “clearance angle” reduces the
surface temperature and wear, and increases pick lifetime. Liu et al. [176] explained that wear
area decreases by increasing the height of the pick tip, pick tip angle and the cutting angle.
Cheluszka et al. [177] found that conical picks have a much longer service life compared to
radial picks, due to the possibility of spontaneous rotation in pick holders, and even wear and
tear of their tip around the entire perimeter. Many coal rock cutting test rigs, as shown in Figure
3, have been developed in order to reveal the cutting performance and pick failure mechanisms
[178,179,180,181,182].
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Figure 3. Development of coal rock cutting test rigs by the pick.
6. Service Safety Evaluation of the Pick Based on Wear and Fatigue
6.1. Pick Wear

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The wear of the pick is important for estimating the downtime of the cutting machines [121].
The degree of pick wear greatly affects the cutting efficiency, energy consumption and service
life of the shearer drum. Therefore, the quantitative evaluation of pick wear is of great theoretical
significance to the determination of pick deterioration grade and prediction of pick service life. In
general, pick wear is mainly measured through the weight loss method [183] and three-
dimensional morphology recovery method [184,185]. Traditional three-dimensional morphology
 
recovery technologies, i.e., the shape from shading method, stereovision method and structured
light method, have limitations in obtaining accurate morphologies [185]. However, the focused
morphology recovery technique has the advantages of non-occlusion, strong practicability, high
accuracy and a simple algorithm, which can make up the limitations of traditional three-
dimensional morphology recovery technologies. In order to obtain the three-dimensional
morphology of pick cone and pick wear rate, the pick wear measurement system has been
established combining the normal distribution operator filtering based on image processing
method, improved focus evaluation function, focused morphology recovery method, and
optimization design method. Figure 4 shows the pick wear measurement system based on the
focused morphology recovery technique [16]. Kim et al. [186,187] investigated the effects of the
skew angle of a pick cutter on its wear phenomenon using a frictional ignition test machine, and
they reported the importance of the skew angle on the wear behavior of a pick cutter.
Figure 4. Pick wear measurement system.
During coal rock cutting, several characteristics (acoustic emission signal, vibration signal,
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current signal, power signal, etc.) can be employed to indirectly reflect the degree of pick wear. It
is proposed that the picks with distinct wear degrees exhibit different characteristics of acoustic
emission signals and vibration acceleration signals during coal-rock cutting [188,189,190]. It is searchmenu
indicated that the amplitudes of vibration acceleration and the acoustic emission signal
increases with increasing wear degree. Furthermore, many scholars have established wear
models of shearer picks using EDEM [191,192], ABAQUS [193], ANSYS [194] and Hyperworks
[195]. Correlation models between operating parameters (rotational speed, installation angle and
pick tip angle) and pick wear degree are established to provide the theoretical basis for the
quantitative evaluation of pick wear [196,197]. Meanwhile, the infrared temperature and current
signals of picks with distinct wear degrees are measured during coal rock cutting tests in order to
 
establish the sample database of multi-feature signals, which can realize the online detection of
pick wear degree [198,199,200]. The training and learning of samples of multi-feature signals
are conducted to establish the neural network feature signal fusion model (Figure 5) to realize
the online monitoring and accurate identification of pick wear degree [201]. In addition, X-ray
technology and support vector machine technology have also been employed in the detection
and prediction modelling of pick wear degree [44,149,202,203]. Tan et al. [204] proposed that
pick wear mechanism was the abrasive wear attributed to the small amount of hard materials
such as A1203 in the coal seam containing gangue. Alber [203] studied the relationship between
the rock Saichal friction coefficient and physical and mechanical properties of the rock, evaluated
the rock abrasiveness and predicted the pick wear loss.
Figure 5. Neural network feature signal fusion model of pick wear degree.
6.2. Quantitative Evaluation of the Service Safety of the Pick

During coal rock cutting, the wear, fatigue and corrosion of the pick causes its gradual
deterioration and thereby the dynamic change of reliability, i.e., gradual reliability (Wang et al.,
2012). As the pick deteriorates to a certain extent and cannot bear the instantaneous impact or
fatigue load, the pick body fractures, greatly affecting the coal rock cutting safety and reliability.
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Previous studies mainly focus on the reliability and reliability sensitivity of the pick, employing
mathematical statistics and probability theory [205], reliability theory [206,207], artificial neural
network and finite element methods. Krzysztof et al. [30] established the reliability model of a searchmenu
rotating pick. Meanwhile, they proposed that the evaluation method based on the average or
extreme value caused the overestimation or underestimation of pick failure risk. Sun [208]
studied the reliability and reliability sensitivity of picks during coal rock cutting, employing the
ANSYS/LS-DYNA, neural network, and first-order second-moment theory (Figure 6a). Zhang
[160] proposed the wear reliability and residual life of pick based on the gamma process and
Bayesian method (Figure 6b).
 
Figure 6. Prediction flow charts of the reliability and residual life of the pick: (a) neural
network and first-order second-moment method, and (b) gamma process and Bayes
method.
Considering the service life and safety factor of pick, Qin [195] investigated the effects of
working conditions and cutting parameters on pick fatigue lives, based on the Radioss fatigue
theory. Meanwhile, the fatigue life and fatigue safety factor of the pick were calculated using
ABAQUS, Fe-Safe, and fatigue accumulation damage theory [209]. Lu et al. [210] analyzed the
effect of the installation angle on pick fatigue life, employing LS-DYNA and Smith–Watson–
Topper multi-axial fatigue life criterion. It is indicated that the reliability and service life of the pick
can be effectively enhanced by adopting the rotating pick [203], improving the layout of picks on
the shearer drum [211], improving structural parameters of the pick [212,213] and selecting high
performance pick material [214,215].
6.3. Methods to Improve the Service Safety of the Pick
Johnson [216] synthesized new materials employing the carburizing treatment on the basis
of a 30CrMnMo alloy, which improved the mechanical performance and wear resistance of the
pick. This could prevent pick fracture and the pick head falling off due to severe load during
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operation, and it was pointed out that tooth corrosion and wear were main forms of pick failure.
Chen et al. [217] employed the plasma surface spraying technology to realize the cladding of
composite coating on the worn surface of the pick in order to improve the wear resistance and searchmenu
corrosion resistance of the pick. Zvonarev et al. [218] predicted the service lives of key parts of
mining machinery by analyses of the energy capacity and energy distribution, and discovered
distribution points of severe wear in the parts through the energy distribution, and improved the
service lives of key parts through hardening treatment. Zhang et al. [219] improved the hardness
and wear resistance of shearer pick body material 40Cr. Li et al. [126] studied the wear degree
of the pick at different helix and locations in the case of the pick cutting hard rock, and found the
main failure forms of pick. Meanwhile, they proposed the brazing, heat treatment, thermal
 
spraying technology and plasma cladding strengthening technologies to treat the pick in order to
improve its service life.
7. Research Prospect
The pick cutting structure is the “tooth” of the automatic shearer. In order to allow for the
efficient cutting of coal seams, it should have high intelligence, high cutting capacity and high
reliability. Complex geological conditions, such as fold structure, fault structure and magmatic
intrusion, induce distinct occurrence conditions of coal rock seams (gangue, inclusion, or fault in
the coal and rock). The adaptive cutting of the shearer reflects the ability of fully mechanized
mining “three machines” equipment to automatically perceive the occurrence of coal seams and
special structural parameters, and to adjust cutting parameters and processes without human
intervention. The degree of adaptability also reflects the level of intelligent mining at the working
face, and thereby the research on adaptive intelligent control methods is the focus of future
research.
The fusion method for coal-rock interface detection should be focused on when dealing with
complex geological conditions. During cutting, the boundary of the coal-rock interface is detected
by hyperspectral or laser visual methods to correct the navigation path of the shearer operation.
This fusion method can solve the problems of low accuracy and practicability of coal rock
interface detection. Meanwhile, the coal mine geological data and the fine geophysical
exploration results of seismic wave CT can be employed to establish the GIS models of the coal
seam roof and floor in the working face. GIS models can effectively identify the coal-rock
interface, and is the basis for realizing the automatic sensing of coal seams and adaptive cutting
of shearers. However, the accuracy of geological exploration needs to be further improved. The
accuracy of coal seam thickness distribution, coal seam roof and floor elevation reflected by the
coal seam geographic information system in the working face is an important factor affecting the
cutting path planning of the shearer. However, according to the current accuracy of seismic CT
fine geophysical exploration, it is not reliable to plan the cutting path completely depending on
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the data of the coal seam geographic information system of the working face. Therefore, the
data precision improvement technology of the coal seam geographic information system of the
working face should be investigated from the perspective of detection methods, or based on the searchmenu
knowledge of coal seam geological experts and historical cutting conditions.
Under complex geological conditions, the effects of geological conditions such as coal rock
gangue, inclusions and small faults on the coal-rock cutting mechanisms are not clear. The coal
rock is heterogeneous and anisotropic due to the influence of geostress and confining pressure.
The composition and performance of the coal wall in different regions are different.
Comprehensive consideration of the working conditions of coal seams, including dirt bands and
inclusions, can provide a more comprehensive scientific basis for the design of shearer spiral
 
drums. The effects of actual working conditions on pick cutting loads should be fully considered,
and the theoretical calculation model of the drum load spectrum should be improved, according
to the different properties of coal in different regions, the most suitable shearer drum parameters,
and kinematic parameters. Meanwhile, the simulation models and theoretical system of coal rock
cutting considering complex geological conditions are not perfect. The prediction accuracy of
load feature recognition models depends on the number of samples. In the future, targeted
sample control expansion should be carried out according to the geological conditions of
different working faces. In order to obtain the force information of the spiral drum in cases of
different working conditions, the coupled discrete element and dynamic simulations can be
employed to reflect the actual working state of the shearer.
Meanwhile, we should establish the pick selection system suitable for different complex
geological conditions (for example, severe pick wear indicating the selection of a pick with high
plasticity and toughness, and a drum and pick with strong breakage capacity in the case of coal
rock with more gangue and faults). It is of great significance to propose the real-time automatic
detection method of shearer pick wear suitable for complex geological conditions, and to
investigate cutting load models for drum picks considering complex geological conditions, which
can enrich the theory of coal-rock cutting using a shearer. There are many factors affecting the
coupling behavior of the shearer spiral drum and coal rock, and its wear characteristics. The
effects of spiral drum structure parameters and temperature field on pick wear should be fully
considered in order to improve the research system of spiral drum wear characteristics in the
subsequent research.
Shearer pick reliability is the quality index of a full life cycle, which covers reliability design,
reliability enhancement, reliable materials, reliability operation and maintenance. It is affected by
the product manufacturing quality and user operation and maintenance level. However, there is
a lack of a digital, networked, intelligent operation and maintenance platform for shearer picks in
cutting coal rock. Meanwhile, only through in-depth study of pick failure can we put forward
corresponding countermeasures regarding aspects of design, manufacturing and use to reduce

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the possibility of pick failure, improve the reliability of pick use, and extend the service life of the
pick. In production practice, this would not only reduce pick use and the purchase cost, but also
greatly shorten the maintenance and replacement time of the pick and improve coal production searchmenu
efficiency. During pick use, the following countermeasures should be taken on site. We have to
strengthen the daily inspection of the shearer pick, especially in the case of special geological
structural zones and hard rocks. The service cycle of the pick should be registered, and the
proportion of new and old picks should be reasonably distributed in order to avoid a large
number of picks entering the fatigue fracture period. We have to strengthen the welding process
of the alloy head and increase the welding strength and impact resistance.
In future researches, we will mainly establish qualitative and quantitative analyses on the
 
gradual deterioration in performances of shearer picks during coal rock cutting under complex
geological conditions, propose a dynamic monitoring system of stresses and strains in shearer
picks, put forward the selection scheme of shearer picks under complex geological conditions,
and obtain the optimal design scheme of arrangement of shearer picks against friction fatigue
failure.
8. Conclusions
The correlations between complex geological conditions and wear deterioration, as well as
the safety and reliability evaluation of shearer picks have been revealed in the present study.
Meanwhile, the influencing factors of wear deterioration of shearer picks have been analyzed. In
order to evaluate coal rock cutting performances of shearer picks under complex geological
conditions, geological occurrence conditions of coal rock seams are classified according to coal
seam thickness and coal lithotype. The mechanical coal rock breakage by shearer picks is
presented through theory, finite and discrete element analyses, and experiment. During coal rock
cutting, the load spectrums of the pick and the mechanical model of the pick force are
discussed. According to the coal rock cutting mechanism, the coal rock cutting process by the
pick, pick failure mechanisms and the development of coal rock cutting test rigs by the pick are
presented. In order to evaluate the service safety of the pick based on wear and fatigue, the pick
wear, quantitative evaluation of service safety of the pick, and methods to improve the service
safety of the pick are introduced. Finally, the research prospect is proposed to outline the
implications for the development trend of coal rock cutting with shearer picks under complex
geological conditions. The present study is of great significance to understand failure modes and
cutting mechanisms of shearer picks, quantitatively evaluate pick safety, promote the automatic
and intelligent cutting of coal rock seams, and thereby to improve the production efficiency of
shearers.
Author Contributions
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Conceptualization, methodology, formal analysis, data curation, writing—original draft
preparation, writing—review and editing, project administration, funding acquisition, L.W.; formal
analysis, data curation, D.W. and C.F.; supervision, D.Z. All authors have read and agreed to the
searchmenu
published version of the manuscript.
Funding
This research was funded by the Fundamental Research Funds for the Central Universities,
grant number 2019QNA13.
 
Institutional Review Board Statement
Not applicable.
Informed Consent Statement
Not applicable.
Data Availability Statement
Not applicable.
Acknowledgments
We would also like to thank contributions of Bo Wang, Hailang Chong, Wei Xu, Yuewei Sun,
Xuefeng Wei, Ziao Xue, Yuan Sun, Liang Tang.
Conflicts of Interest
The authors declare no conflict of interest. We identify and declare there are no personal
circumstances or interest that may be perceived as inappropriately influencing the
representation or interpretation of reported research results. The funders had no role in the
design of the study; in the collection, analyses, or interpretation of data; in the writing of the
manuscript; or in the decision to publish the results.
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Wang, L.; Zhang, D.; Wang, D.; Feng, C. A Review of Selected Solutions on the Evaluation of
Coal-Rock Cutting Performances of Shearer Picks under Complex Geological Conditions. Appl.
Sci. 2022, 12, 12371. https://doi.org/10.3390/app122312371
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Wang L, Zhang D, Wang D, Feng C. A Review of Selected Solutions on the Evaluation of Coal-
Rock Cutting Performances of Shearer Picks under Complex Geological Conditions. Applied
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 2022; 12(23):12371. https://doi.org/10.3390/app122312371 
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Wang, Linlin, Dekun Zhang, Dagang Wang, and Cunao Feng. 2022. "A Review of Selected
Solutions on the Evaluation of Coal-Rock Cutting Performances of Shearer Picks under
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11/1/23, 4:12 PM Applied Sciences | Free Full-Text | A Review of Selected Solutions on the Evaluation of Coal-Rock Cutting Performances of Shear…

12-12371-g006.png?1670307061) Versions Notes (/2076-3417/12/23/12371/notes)

Figure 1. The fully mechanized coal mining face.

2. Occurrence Conditions of Coal Rock Seams

Figure 2. Geological occurrence conditions of coal rock.

Table 2. Classification of coal lithotype.

3. Mechanical Coal-Rock Breakage of Coal Rock by Shearer Picks

Table 3.(/)Research progress on the pick cutting coal-rock.

4. Shearer Pick Forces during Coal-Rock Cutting

4.1. Load Spectrums of the Pick

Table 4. Influence factors of shearer pick vibration.

Table 5. Field tests of shearer pick forces.

5. The Coal-Rock Cutting Mechanism

Table 6. Commonly used pick materials.

6. Service Safety Evaluation of the Pick Based on Wear and Fatigue

6.1. Pick Wear

Figure 4. Pick wear measurement system.

6.2. Quantitative Evaluation of the Service Safety of the Pick

corresponding countermeasures regarding aspects of design, manufacturing and use to reduce

Informed Consent Statement

Data Availability Statement

11. Li, C.L.;

25. Cui, (/)

42. Garbiec, D.; Siwak, P. Microstructural evolution and development of mechanical

57. Ma, (/)

86. Li, X.H.;

87. Song, P. Research on Vibration Characteristics and Transmission System Structure

92. Liu, C.S.

93. Zhang, D. Multi-Tooth Composite Cutting Drum Reconstruction Algorithm of Random

108. He, J.Q.;

113. Liu, X.H.

138. Thuro, K.; Plinninger, R.J. Roadheader excavation performance—Geological and

139. McFeat-Smith, I. Correlation of Rock Properties and Tunnel Machine Performance in

176. Liu, (/)

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