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.

To address the broadband noise distribution, complex excitation sources, and insufficient low-frequency attenuation of conventional porous acoustic packages in commercial vehicle cabs, this study proposes a PU–six-cavity Helmholtz metamaterial composite acoustic package for broadband noise reduction. The proposed structure consists of a 30 mm PU porous layer for mid-to-high-frequency dissipation and a 30 mm six-cavity Helmholtz metamaterial layer for low-frequency absorption, forming a 60 mm composite acoustic package. A full-vehicle acoustic model of a commercial vehicle cab was established in VA One to identify the A-weighted sound pressure level (SPL) spectrum at the driver position. The results show that the PU porous acoustic package improves the mid- and high-frequency noise response, whereas pronounced peaks remain in the low- and low-to-mid-frequency ranges. To enhance these bands, the six sub-cavities of the Helmholtz metamaterial were tuned to 200, 250, 315, 400, 500, and 630 Hz through spatial partitioning and cavity grouping. COMSOL (version 6.1) simulations and particle velocity distributions confirmed the multi-peak absorption mechanism and the selective excitation of the corresponding sub-cavities. The composite structure was further validated through impedance-tube measurements, full-vehicle acoustic simulations, and in-vehicle tests. The VA One simulation shows that the total A-weighted SPL at the driver position decreases from 68.25 dB for the PU porous package to 66.01 dB after introducing the six-cavity Helmholtz metamaterial, corresponding to an additional reduction of 2.24 dB. A preliminary in-vehicle test under a stationary idling condition shows that the total A-weighted SPL near the driver’s ear decreases from 55.83 dB(A) to 54.56 dB(A). These results demonstrate that the proposed PU–six-cavity Helmholtz metamaterial composite acoustic package combines broadband porous dissipation with low-frequency resonant absorption, providing a feasible solution for broadband noise control in commercial vehicle cabs.