小断面矩形掘进机仿形刀盘设计方法研究

Study on Design Method of Profile Cutterhead for Small Section Rectangular TBMs

仿形刀盘设计是小断面矩形掘进机研制过程中的关键技术,直接关系到隧道成型质量和设备利用率。提出了一种利用行星式传动机构进行小断面矩形隧道全断面开挖的仿形刀盘设计方法,基于刀盘轮廓与断面滚动相切的仿形原理,建立了刀盘轮廓的理论模型,在此基础上对刀盘切削轨迹和开挖面进行分析,指出直角矩形边角超挖不可避免,通过确定刀盘最优中心距、设置矩形圆角、优化刀盘轮廓,实现了圆角矩形隧道的全断面开挖。进一步通过刀盘轮廓质点的运动规律分析,依据刀具磨损等寿命原则,提出仿形刀盘刀具布置策略。结合日本2 m级矩形掘进机在砂砾层中的掘进试验,验证了刀盘设计方法的可行性,研究成果为小断面矩形掘进机仿形刀盘设计提供了理论依据。

The profile cutterhead design is the key technology in the development of small section rectangular TBMs,which is directly related to tunnel formation quality and TBM utilization.A design method of profiling cutterhead for full section excavation of small section rectangular tunnel with planetary transmission mechanism was presented.Based on the principle of the tangency of cutter profile and section edge,a theoretical profile model of cutter head contour was established.Based on the model,the cutting path and the excavation face were analyzed.It is pointed out that the overbreak of the right angle rectangular corner is inevitable.By determining the optimal center distance of the cutterhead,adding the rectangular round corners and optimizing the cutterhead contour,the full section excavation of rectangular tunnel with rounded corner was realized.Furthermore,by analyzing the motion of the discrete points of the cutterhead contour,according to the equal-life principle of tool wear,the configuration strategy of profiling cutter layout was put forward.Finally,the feasibility of cutterhead design method was verified with the tunneling test of Japanese 2 m rectangular TBMs in gravel layer.The research results provide a theoretical foundation for the design of profiling cutterhead for small section rectangular TBMs.