Dynamic mechanical characteristics and engineering application of high elongation anchor cable
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摘要:
传统锚索延伸率低、抗冲击能力差，在强冲击载荷作用下易出现脆性破断失效，导致巷道出现冒顶、冲击地压事故等问题。基于此，自主开发了具有高强度、高延伸率及高抗冲击等特性的锚索，采用实验室试验、理论分析及现场试验等综合手段，分析了高延伸率锚索的静、动载力学性能，研究了高延伸率锚索化学成分、金相组织和夹杂物与普通锚索的差异，提出了高延伸率锚索支护吸能原理，并将高延伸率锚索在现场进行了应用。研究结果表明：静载作用下，高延伸率锚索抗拉强度为1 790 MPa，最大力总延伸率8.1%，是普通锚索的1.61～2.25倍；动载作用下，高延伸率锚索钢丝不易散开，破断载荷与普通锚索基本相同，断后伸长率分别是锚索A、B、C的1.82倍、1.68倍和1.52倍，单位长度吸能量分别是锚索A、B、C的2.54倍、1.99倍和1.70倍，高延伸率锚索塑性变形能力更强，吸能能力更高。高延伸率锚索通过在冶炼和轧制工艺过程中控制有害化学元素和有益化学元素含量、细化金相组织及减少夹杂物尺寸和数量等方式提高了钢丝的塑性变形能力，进而提高锚索整体的抗冲击性能。高延伸率锚索在现场应用过程中经受了多次大能量冲击后，巷道支护效果良好，高延伸率锚索未出现破断，有效控制了巷道冲击破坏。
Abstract:The traditional anchor cable has low elongation, poor impact resistance, and is prone to brittle fracture failure under strong impact load, leading to roof fall, rock burst accidents and other problems in the roadway. Based on this, the anchor cable with high strength, high elongation and high impact resistance was independently developed. The static and dynamic mechanical properties of the anchor cable with high elongation were analyzed by laboratory tests, theoretical analysis and field tests. The differences between high elongation anchor cable and ordinary anchor cable in chemical composition, metallographic structure and inclusion are also studied. Finally, the energy absorption principle of high elongation anchor cable support is proposed, and the high elongation anchor cable is applied in the field. The results show that: Under static load, the tensile strength of high elongation anchor cable is
1790 MPa, the total elongation of maximum force is 8.1%, which is 1.61−2.25 times of that of ordinary anchor cable. Under dynamic load, the steel wire of high elongation anchor cable is not easy to disperse, and the breaking load is basically the same as that of ordinary anchor cable. The elongation after breaking is 1.82 times, 1.68 times and 1.52 times of that of anchor cable A, B and C, respectively. The energy absorption per unit length is 2.54 times, 1.99 times and 1.70 times of that of anchor cable A, B and C, respectively. The high elongation anchor cable has stronger plastic deformation capacity and higher energy absorption capacity. The high elongation anchor cable improves the plastic deformation ability of the steel wire by controlling the content of harmful and beneficial chemical elements, refining the metallographic structure and reducing the size and quantity of inclusions in the smelting and rolling process, thereby improving the overall impact resistance of the anchor cable. After the high elongation anchor cable has withstood many large energy shocks in the field application process, the roadway support effect is good, and the high elongation anchor cable has not broken, effectively controlling the roadway impact damage.-
Keywords:
- rock burst /
- deep roadway /
- bolt support /
- drop hammer /
- high elongation anchor cable
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图 4 锚索试样冲击后变形破坏情况
Figure 4. Deformation and damage of anchor cable sample after impact
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图 6 4种锚索断后伸长率和吸能特性对比
Figure 6. Comparison of elongation and energy absorption characteristics of four kinds of anchor cables after fracture
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图 11 锚杆和锚索联合支护吸能曲线示意
Figure 11. Schematic diagram of energy absorption curve for combined support of bolts and cables
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图 12 义马矿区典型巷道变形破坏情况
Figure 12. Deformation and failure of typical roadways in Yima mining area
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图 14 锚索受力和冲击能量关系曲线
Figure 14. Relation curve between axial force and impact energy of anchor cable
表 1 巷道冲击地压典型事故案例
Table 1 Typical accident cases of roadway rock burst
基本信息 内容描述 现场图片 义马矿区耿村矿“12·22”冲击地压事故 工程概况 事故发生在13230工作面下巷，位于东三采区(2–3)轨道下山东翼，北侧为采空区，西侧和南侧均为未开采的2–3煤，埋深700 m，煤层厚度10.4 m，煤层倾角9°～13°。巷道为留底煤布置，底煤厚度0.5～6.20 m。直接顶为泥岩，平均厚度31.5 m，泥岩上部存在巨厚砾岩，厚度380 m。巷道采用锚网索+36U棚复合支护，锚索直径17.8 mm，最大力总延伸率3.5%。未冲击区域顶板锚索受力在170～350 kN，巷帮锚索受力在150～210 kN 
围岩变形
破坏特征“12·22”冲击地压事故造成工作面运输巷道超前工作面160 m巷道被损毁，震级2.1级，冲击能量6.3×105 J，巷道高度由冲击的4.15 m降低至1.7 m，宽度由冲击前的6.2 m降低至1.8 m。顶板大量锚索出现破断，液压抬棚损坏30架，转载机移位、翻倒，输送带侧翻、压死 门克庆煤矿“4·8”冲击地压事故 工程概况 事故发生在3102工作面回风巷，回风巷煤柱尺寸35 m，埋深677～707 m。直接顶为粉砂岩，厚度4.70 m，基本顶为细砂岩，厚度18.48 m。直接底为粉砂岩，厚度10.29 m，基本底为细砂岩，厚度21.90 m。煤层上部35 m处存在一层厚硬中粒砂岩，厚度达到62 m。巷道采用锚网索支护，锚索直径21.8 mm，最大力总延伸率5.0%。未冲击区域顶板锚索受力在140～260 kN，巷帮锚索受力在90～230 kN 
围岩变形
破坏特征“4·8”冲击地压事故造成90 m巷道出现强烈破坏，监测到的冲击能量达3.3×107 J，工作面人员听到巨响煤炮，工作面支架工作阻力出现剧增，单体压弯、巷道顶板锚杆、锚索出现破断，巷道出现强烈变形，顶板下沉严重，帮部煤体抛出，底板隆起，巷道出现堵塞，局部区域巷道已闭合 彬长胡家河矿“10·11”冲击地压事故 工程概况 事故发生在402104工作面回风巷，煤层厚度23 m，埋深650 m，煤柱尺寸40 m。直接顶为砂质泥岩，厚度6.03 m，基本顶为中砂岩，厚度35.95 m。直接底为炭质泥岩，厚度1.10 m，基本底为泥岩，厚度4.79 m。巷道采用锚网索支护，锚索直径21.8 mm，最大力总延伸率5.0%。未冲击区域顶板锚索受力在160～420 kN，巷帮锚索受力在130～260 kN 
围岩变形
破坏特征“10·11”冲击地压事故造成70 m巷道严重破坏，监测到的冲击能量超过106 J，防冲支架出现不同程度的立柱弯折、爆缸等破坏，大量的锚杆和锚索出现破断失效，顶板严重下沉，巷帮鼓出，底板隆起，巷道严重地段出现闭合、堵塞 吉林龙家堡煤矿“6·9”冲击地压事故 工程概况 事故发生在305综放工作面运输巷，距离开切眼85～305 m，主采3号煤层，煤层厚度10 m，煤层开采深度850～980 m。伪顶为炭质泥岩厚0.3 m，直接顶为黑色、灰色泥岩，厚5～30 m。巷道采用锚网索支护，锚索直径21.8 mm，最大力总延伸率5.0%。未冲击区域顶板锚索受力在160～280 kN，巷帮锚索受力在120～240 kN 
围岩变形
破坏特征“6·9”冲击地压事故造成220 m巷道严重破坏，冲击能量达1.55×108 J，支架几乎全部以立柱弯曲、爆缸、折断等方式损坏，U型钢棚变形严重，部分被折断。部分锚杆被整体推出，锚索出现大量破断失效 
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表 2 锚索力学性能测试结果
Table 2 Test results of mechanical properties of anchor cable bearing capacity
型号 公称直径/mm 破断载荷/kN 抗拉强度/MPa 屈服强度/MPa 最大力总延伸率/% 1×7股锚索 21.6 530 1860 1 600 3.6 21.6 532 1860 1 600 3.5 21.6 528 1860 1 620 3.7 1×19股锚索 21.8 560 1810 1570 5.0 21.8 566 1820 1560 5.1 21.8 554 1800 1560 5.0 高延伸率锚索 21.8 560 1 790 1 550 8.2 21.8 562 1 800 1 550 8.0 21.8 561 1 790 1 560 8.1
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表 3 4种锚索断后伸长率和单位长度吸能量
Table 3 Elongation and energy absorption per unit length of four kinds of anchor cables after breaking
锚索类型 断后位移/mm 断后伸长率/% 单位长度吸能/kJ 锚索A 46.80 2.46 6.01 锚索B 50.70 2.67 7.67 锚索C 56.00 2.95 8.95 高延伸率锚索 85.10 4.48 15.24
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表 4 锚索钢材化学成分
Table 4 Chemical composition of anchor cable steel
锚索类型 各元素质量分数/% C Si Mn P S Cr Ni Cu 锚索A 0.84 0.19 0.77 0.010 0.008 5 0.16 0.018 0.041 锚索B 0.83 0.20 0.78 0.013 0.011 0.17 0.027 0.060 锚索C 0.82 0.22 0.62 0.014 0.004 1 0.27 0.012 0.014 高延伸率锚索 0.79 0.22 0.83 0.011 0.003 6 0.20 0.011 0.014
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表 5 4种锚索夹杂物等级
Table 5 Inclusion level of 4 kinds of anchor cables
锚索类型 非金属夹杂物(等级) A B D 锚索A 1.5 2.5 0.5 锚索B 1.0 2.0 0.5 锚索C 1.0 2.0 0.5 高延伸率锚索 0.5 1.0 0.5
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表 6 不同类型煤矿对锚索选择的要求
Table 6 Requirements for cable selection in different types of coal mines
巷道类型 锚索类型 锚索直径/mm 最大力总延伸率/% 无冲击危险 普通锚索 18.9～21.8 3.5～5.0 弱冲击危险 普通锚索 21.8 ≥5.0 中等冲击危险 高延伸率锚索 21.8 ≥7.0 强冲击危险 高延伸率锚索 21.8 ≥8.0
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