Failure mechanism of tip-to-face roof based on energy method and experimental investigation of support-strata interaction

In order to study the stability and influencing factors of the end face roof of the full-mechanized mining face, a mechanical model of tip-to-face roof stability was developed in this study with a combination of the energy method and the “roof-support-coal” system. Meanwhile, the load monitoring system on the canopy of the support and the digital image measuring technique were utilized in a physical simulation model to analyze the influence factors of tip-to-face roof fall, the roof failure characteristics and the evolution characteristics of pressure distribution on the canopy of the support. The results showed that the stability coefficient of the immediate roof within 1 m behind the coal wall was less than 0 based on the mechanical model of tip-to-face roof stability, indicating a high risk of roof collapse in this area. In addition, the vertical and horizontal displacement of the immediate roof increased with the increase of the distance behind the coal wall. Enhancing the working resistance of the support can also reduce the roof subsidence, and the higher roof cohesion and internal friction angle can improve the tip-to-face roof stability. On the other hand, the tip-to-face roof caving, roof broken and roof crushing were observed in sequence during the process of the physical simulation experiments. The middle section of the canopy showed the largest measured pressure, followed by the front and rear sections of the canopy in the descending order. When the roof was intact, the support showed adequate setting load and working resistance, and the interaction between the support and the strata was in good condition. As the roof was broken and led to an unfavorable support position, the support showed a loss of working resistance or an unbalanced loading condition, which may easily result in the crack development in the roof, tip-to-face roof cavity, an iron-bound support and an awful support-strata coupling. According to the digital image measuring technique, the maximum shear strain was found near the tip-to-face area during the tip-to-face roof caving stage. Lastly, it can be concluded that the coupling between the support and strata is closely correlated to the tip-to-face roof stability. Thus, maintaining a good support-strata interaction is beneficial to the stability of the tip-to-face roof.