基于TBM刀盘结构分析的滚刀布局设计（英文）

Layout design for disc cutters based on analysis of TBM cutter-head structure

目前,滚刀布局设计研究中存在许多不足,如边滚刀变切深的特性,刀盘焊缝的约束条件,刀盘剖面轮廓与滚刀极径布置的耦合机制问题等均未被考虑和重视。为解决这些问题,笔者提出了一种基于刀盘剖面轮廓和焊缝约束条件的刀具布局的适应性设计方法。以最外侧刀具的轴承受力为评价准则,给出平面刀盘的剖面轮廓设计方法;采用GA算法,基于等寿命原则和等磨损原则,对边刀的倾斜角进行了优化设计;给出了对滚刀进行星型布置时,滚刀与滚刀、人孔、出渣槽以及焊缝之间不干涉的边界条件;采用各指标在邻近两次布局中的相对优化提高度进行量纲的一致性处理,建立了刀盘的综合评价模型,完成刀具的周向布置。以MB264-311-8030 mm型TBM刀盘为案例,计算结果表明,与原始滚刀的布局相比,51把滚刀中,极径的最大差距仅有25.8 mm,相对于刀盘的半径大小为0.64%,极小;刀盘的径向不平衡力减少了62.41%,倾覆力矩减少了33.22%,质心偏斜量仅增加了18.48%,各指标都优于或近似等于原始刀盘布局结果;刀盘的应力和变形均小于原始刀盘,有效地验证了模型的可行性。

Studies to date have failed to consider gage disc cutters’variable cutting depth and the constraints of cutter-head welds,and have ignored the coupling mechanism between the profile of the full-face rock tunnel-boring machine(TBM)cutter-head and the assembled radius layout of the disc cutters.To solve these problems,an adaptive design method for studying cutter layout was proposed.Taking the bearing stress of the outermost gage disc cutter as an index,the profile of the cutter-head was determined.Using a genetic algorithm and based on the principles of equal life and equal wear,the assembled radii of the cutters were optimally designed.Boundary conditions of non-interference between the cutters,manholes,muck buckets and welding lines were given when a star layout pattern was used on cutters.The cutter-head comprehensive evaluation model was established by adopting relative optimization improvement degree of evaluation indices to achieve dimensional consistency.Exemplifying the MB264-311-8030 mm tape TBM cutter-head,the calculations show that compared with the original layout scheme,among the 51 disc cutters,the largest gap of the cutters’assembled radiuses is only 25.8 mm,which is 0.64%of the cutter-head’s radius and is negligible.The cutter-head’s unbalanced radial force decreases by 62.41%,the overturning moment decreases by 33.22%,and the cutter group’s centroid shift increases by only 18.48%.Each index is better than or approximately equal to the original cutter-head layout scheme,and the equivalent stress and deformation are both smaller;these results fully verify the feasibility and effectiveness of the method.