基于磨料磨损的TBM滚刀磨损预测研究

Study of wear prediction for TBM cutter based on abrasive wear model

为准确预测滚刀磨损量及其寿命,通过分析滚刀工作工况及磨损后表面形貌,得出以磨料磨损为主要形式的滚刀磨损中,引起刀圈表面材料去除的机制主要是基于塑性去除的显微切削与犁沟去除,以及基于韧性断裂去除的微观断裂剥离,硬度低韧性高的滚刀以发生塑性去除机制为主,硬度高韧性低时以发生断裂去除机制为主。通过推导塑性去除机制与韧性断裂去除机制产生的磨损量计算式,并利用图像处理技术对滚刀磨损表面SEM图像进行处理确定这2种机制所产生的磨损量之比,建立耦合这2种去除机制的滚刀磨损量预测公式,并在多功能硬岩滚刀试验台上进行实验验证,实验结果表明预测模型能较准确地反映滚刀的实际磨损。

In order to predict the worn volume and working life of TBM cutter,main removal mechanisms of abrasive wear were obtained based on the working conditions and worn surface morphology of cutter ring. The main wear forms of cutter were micro cutting or furrow removal due to plastic removal and microscopic fracture mechanism because of toughness removal. The main wear mechanisms of cutter with low hardness and high toughness were plastic removal,while cutter with high hardness and low toughness was fracture removal. By deducing the formula of wear volume produced by plastic removal mechanism and toughness removal mechanism,and calculating the proportion produced by the two mechanisms through image processing to SEM photo of cutter＇s worn surfaces,a wear prediction model of the cutter that coupling the two mechanisms was established. Experimental verification in the multi-function test bed of hard rock cutter was carried out. The experimental results show that this prediction model can reflect the actual wear of the cutter accurately.