At present, the inner cutters of a full face rock tunnel boring machine (TBM) and transition cutter edge angles are designed on the basis of indentation test or linear grooving test. The inner and outer edge angles of...At present, the inner cutters of a full face rock tunnel boring machine (TBM) and transition cutter edge angles are designed on the basis of indentation test or linear grooving test. The inner and outer edge angles of disc cutters are characterized as symmetric to each other with respect to the cutter edge plane. This design has some practical defects, such as severe eccentric wear and tipping, etc. In this paper, the current design theory of disc cutter edge angle is analyzed, and the characteristics of the rock-breaking movement of disc cutters are studied. The researching results show that the rotational motion of disc cutters with the cutterhead gives rise to the difference between the interactions of inner rock and outer rock with the contact area of disc cutters, with shearing and extrusion on the inner rock and attrition on the outer rock. The wear of disc cutters at the contact area is unbalanced, among which the wear in the largest normal stress area is most apparent. Therefore, a three-dimensional model theory of rock breaking and an edge angle design theory of transition disc cutter are proposed to overcome the flaws of the currently used TBM cutter heads, such as short life span, camber wearing, tipping. And a corresponding equation is established. With reference to a specific construction case, the edge angle of the transition disc cutter has been designed based on the theory. The application of TBM in some practical project proves that the theory has obvious advantages in enhancing disc cutter life, decreasing replacement frequency, and making economic benefits. The proposed research provides a theoretical basis for the design of TBM three-dimensional disc cutters whose rock-breaking operation time can be effectively increased.展开更多
为了对比不同典型全断面岩石掘进机(TBM)刀盘的力学性能,对刀盘倾覆力矩计算模型进行了修正。在理想工况、上软下硬地质和部分刀具磨损3种工况下,计算得到刀盘倾覆力矩的分布情况,并采用有限元法模拟得到刀盘掘进过程中应力分布规律。...为了对比不同典型全断面岩石掘进机(TBM)刀盘的力学性能,对刀盘倾覆力矩计算模型进行了修正。在理想工况、上软下硬地质和部分刀具磨损3种工况下,计算得到刀盘倾覆力矩的分布情况,并采用有限元法模拟得到刀盘掘进过程中应力分布规律。结果表明:刀盘的径向载荷远小于刀盘倾覆力矩,倾覆力矩对刀盘性能的影响远大于径向载荷;刀盘正面滚刀受载产生的倾覆力矩最大,其次是边缘滚刀,中心滚刀受载产生的倾覆力矩最小;在刀具磨损工况下,A刀盘总倾覆力矩在2 800 k N·m以上,比理想工况下要大7%;星形布局刀盘B的倾覆力矩比螺旋线布局刀盘A小,其力学性能和强度特性优于螺旋线布局刀盘。展开更多
The success of a tunnel-boring machine （TBM） in a given project depends on the functionality of all components of the system, from the cutters to the backup system, and on the entire rolling stock. However, no part ...The success of a tunnel-boring machine （TBM） in a given project depends on the functionality of all components of the system, from the cutters to the backup system, and on the entire rolling stock. However, no part of the machine plays a more crucial role in the efficient operation of the machine than its cutterhead. The design of the cutterhead impacts the efficiency of cutting, the balance of the head, the life of the cutters, the maintenance of the main bearing/gearbox, and the effectiveness of the mucking along with its effects on the wear of the face and gage cutters/muck buckets. Overall, cutterhead design heavily impacts the rate of penetration （ROP）, rate of machine utilization （U）, and daffy advance rate （AR）. Although there has been some discussion in commonly available publications regarding disk cutters, cutting forces, and some design features of the head, there is limited literature on this subject because the design of cutter- heads is mainly handled by machine manufacturers. Most of the design process involves proprietary algorithms by the manufacturers, and despite recent attention on the subject, the design of rock TBMs has been somewhat of a mystery to most end-users. This paper is an attempt to demystify the basic concepts in design. Although it may not be sufficient for a full-fledged design by the readers, this paper allows engineers and contractors to understand the thought process in the design steps, what to Look for in a proper design, and the implications of the head design on machine operation and life cycle.展开更多
基金supported by National Natural Science Foundation of China (Grant No. 51075147)
文摘At present, the inner cutters of a full face rock tunnel boring machine (TBM) and transition cutter edge angles are designed on the basis of indentation test or linear grooving test. The inner and outer edge angles of disc cutters are characterized as symmetric to each other with respect to the cutter edge plane. This design has some practical defects, such as severe eccentric wear and tipping, etc. In this paper, the current design theory of disc cutter edge angle is analyzed, and the characteristics of the rock-breaking movement of disc cutters are studied. The researching results show that the rotational motion of disc cutters with the cutterhead gives rise to the difference between the interactions of inner rock and outer rock with the contact area of disc cutters, with shearing and extrusion on the inner rock and attrition on the outer rock. The wear of disc cutters at the contact area is unbalanced, among which the wear in the largest normal stress area is most apparent. Therefore, a three-dimensional model theory of rock breaking and an edge angle design theory of transition disc cutter are proposed to overcome the flaws of the currently used TBM cutter heads, such as short life span, camber wearing, tipping. And a corresponding equation is established. With reference to a specific construction case, the edge angle of the transition disc cutter has been designed based on the theory. The application of TBM in some practical project proves that the theory has obvious advantages in enhancing disc cutter life, decreasing replacement frequency, and making economic benefits. The proposed research provides a theoretical basis for the design of TBM three-dimensional disc cutters whose rock-breaking operation time can be effectively increased.
文摘为了对比不同典型全断面岩石掘进机(TBM)刀盘的力学性能,对刀盘倾覆力矩计算模型进行了修正。在理想工况、上软下硬地质和部分刀具磨损3种工况下,计算得到刀盘倾覆力矩的分布情况,并采用有限元法模拟得到刀盘掘进过程中应力分布规律。结果表明:刀盘的径向载荷远小于刀盘倾覆力矩,倾覆力矩对刀盘性能的影响远大于径向载荷;刀盘正面滚刀受载产生的倾覆力矩最大,其次是边缘滚刀,中心滚刀受载产生的倾覆力矩最小;在刀具磨损工况下,A刀盘总倾覆力矩在2 800 k N·m以上,比理想工况下要大7%;星形布局刀盘B的倾覆力矩比螺旋线布局刀盘A小,其力学性能和强度特性优于螺旋线布局刀盘。
文摘The success of a tunnel-boring machine （TBM） in a given project depends on the functionality of all components of the system, from the cutters to the backup system, and on the entire rolling stock. However, no part of the machine plays a more crucial role in the efficient operation of the machine than its cutterhead. The design of the cutterhead impacts the efficiency of cutting, the balance of the head, the life of the cutters, the maintenance of the main bearing/gearbox, and the effectiveness of the mucking along with its effects on the wear of the face and gage cutters/muck buckets. Overall, cutterhead design heavily impacts the rate of penetration （ROP）, rate of machine utilization （U）, and daffy advance rate （AR）. Although there has been some discussion in commonly available publications regarding disk cutters, cutting forces, and some design features of the head, there is limited literature on this subject because the design of cutter- heads is mainly handled by machine manufacturers. Most of the design process involves proprietary algorithms by the manufacturers, and despite recent attention on the subject, the design of rock TBMs has been somewhat of a mystery to most end-users. This paper is an attempt to demystify the basic concepts in design. Although it may not be sufficient for a full-fledged design by the readers, this paper allows engineers and contractors to understand the thought process in the design steps, what to Look for in a proper design, and the implications of the head design on machine operation and life cycle.
