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-borin...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.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Projects(51275339,51575379,51675374)supported by the National Natural Science Foundation of ChinaProject(2013CB035402)supported by the National Hi-tech Research and Development Program of China
文摘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.
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.
