Cantilever roadheaders are widely used in medium-soft rock tunneling. However, conventional pick cutters suffer from high rock-breaking load, excessive energy consumption, and severe abrasion, which restrict the performance of roadheader vehicle-end intelligent control systems. Existing ultrasonic rock-breaking studies mainly focus on drilling and polycrystalline diamond compact (PDC) cutters, while calibrated EDEM simulation and experimental studies of synchronous ultrasonic-vibration-assisted pick cutter cutting remain limited. This study investigates the rock-breaking behavior of synchronous ultrasonic vibration coupled with pick cutter cutting using 21 MPa artificial rock-like specimens. A calibrated EDEM simulation model was developed based on the Hertz–Mindlin with Bonding contact model and validated by uniaxial compression and Brazilian splitting tests. Meta-particle technology was applied to analyze fragmentation characteristics. The effects of ultrasonic frequency, cutting angle, and cone angle on rock-breaking load, debris production, and specific energy consumption were investigated through simulations and experiments. An ultrasonic-assisted cutting test system equipped with force sensors was established for validation. Results show that 30 kHz ultrasonic vibration effectively reduces rock-breaking load under the investigated operating conditions. A relatively favorable parameter combination obtained from the numerical simulations consists of an ultrasonic frequency of 30 kHz, a cutting angle of 40°, and a cone angle of 60°. Compared with conventional cutting, the optimized scheme reduces average cutting load by 74.69%, increases debris yield by 54.71%, and decreases mass-specific mechanical cutting energy consumption by 83.63%. This study provides quantitative data support for roadheader vehicle-end intelligent control systems.

A common engineering challenge is that a single sound-absorbing material cannot adequately cover the full frequency range in broadband noise control of commercial vehicle cabs; with the aim of addressing this challenge, this study employs a synergistic noise reduction method integrating hybrid finite element–statistical energy analysis (FE–SEA) with foam mixture design. A hybrid FE–SEA cab model is first established, and panel contribution analysis is used to identify key radiating areas such as the floor and rear panel, as well as their corresponding energy-concentrated frequency bands. High- and low-flow-resistance polyurethane foams and melamine foam are selected as base materials. A simplex-centroid mixture design is adopted to construct a Scheffé regression model using the average noise reduction contribution in frequency bands as the response, and Derringer–Suich multi-response optimization is applied to obtain the optimal proportions. Full-vehicle simulation results show that the optimized formulation achieves noise reduction contributions of 13.87, 16.42, and 10.84 dB in the 200–500 Hz, 800–1600 Hz, and 2000–3150 Hz bands, respectively, without evident weak-band performance, reducing the overall SPL to 68.25 dB(A). The proposed method establishes a bidirectional linkage between vehicle acoustic response and material formulation, providing a reproducible framework for the forward design and broadband acoustic optimization of commercial vehicle acoustic packages.