Abstract
In deep coal mines, roadway supports endure intense impact ground pressure from rock bursts, severely challenging the load-bearing capacity of underground support equipment. Yet, research on the energy buffering mechanisms of disc springs under such loads remains scarce, impeding the development of optimized impact-resistant support structures for underground environments. This study aims to design a novel modular disc spring-type buffering and energy-absorbing device installed on hydraulic support top beams to mitigate impact damage (e.g., column fracture, cylinder explosion) caused by rock bursts. A hybrid methodology integrating physical drop hammer impact tests (validated using pressure sensors) and dynamic simulations was employed. An ADAMS dynamic simulation model was constructed to compare performance discrepancies between flexible and rigid Disc Spring Composite Monomers under variable loads ranging from 0 to 7500 kg. The flexible Disc Spring Composite Monomer reduced peak support reaction by 10% versus rigid counterparts, exhibited higher rebound height and longer buffering time, and effectively suppressed displacement mutation; its load-deformation relationship followed a sub-linear growth trend, showing high sensitivity at low loads and stiffness-driven saturation at high loads. Flexible Disc Spring Composite Monomers demonstrate superior energy absorption, peak load suppression, and stability against repeated impacts, providing a new technical pathway for impact-resistant roadway support design.