IMPROVEMENT OF MACHINING ACCURACY OF CANTILEVER BORING BAR SYSTEM USING PIEZOELECTRIC ACTUATOR

This paper is concerned with the work involved in improving the machining accuracy of a cantilever boring bar by on line compensation with a piezoelectric actuator. A boring bar is made into lever structure, with strain gauges attached to the bar for measuring its force induced deflections. The piezoelectric actuator is employed to compensate the deflections of the boring bar for accuracy improvement. Due to the mechanical advantage of the structure, the boring bar can be made into smaller size. The diameter of the bar implemented is 10 mm and the ratio of length to diameter (L/D) is larger than 8. It is found that the machining accuracy is improved considerably by using the piezoelectric actuator compensation system.

Effects of data smoothing and recurrent neural network(RNN)algorithms for real-time forecasting of tunnel boring machine(TBM)performance

Tunnel boring machines(TBMs)have been widely utilised in tunnel construction due to their high efficiency and reliability.Accurately predicting TBM performance can improve project time management,cost control,and risk management.This study aims to use deep learning to develop real-time models for predicting the penetration rate(PR).The models are built using data from the Changsha metro project,and their performances are evaluated using unseen data from the Zhengzhou Metro project.In one-step forecast,the predicted penetration rate follows the trend of the measured penetration rate in both training and testing.The autoregressive integrated moving average(ARIMA)model is compared with the recurrent neural network(RNN)model.The results show that univariate models,which only consider historical penetration rate itself,perform better than multivariate models that take into account multiple geological and operational parameters(GEO and OP).Next,an RNN variant combining time series of penetration rate with the last-step geological and operational parameters is developed,and it performs better than other models.A sensitivity analysis shows that the penetration rate is the most important parameter,while other parameters have a smaller impact on time series forecasting.It is also found that smoothed data are easier to predict with high accuracy.Nevertheless,over-simplified data can lose real characteristics in time series.In conclusion,the RNN variant can accurately predict the next-step penetration rate,and data smoothing is crucial in time series forecasting.This study provides practical guidance for TBM performance forecasting in practical engineering.

High-accuracy turning with slender boring bars

The paper presents the theoretical background for new approaches for achieving high accuracy in finish turning with slender tools. The approaches are developed especially for high-accuracy turning with vibrations- damped boring bars with a length-to-diameter ratio up to 14. The approaches are based on established force models of turning operations and utilize a three-pass scheme where the deflection of the boring bar is calculated and compen- sated for in the final passes. Very good results are achieved in practical machining tests for a great variation of cutting conditions. Experiments show that the typical diameter error is 0.01 mm, even in situation where the tool deflection is 0.3 mm.

Tunnelling performance prediction of cantilever boring machine in sedimentary hard-rock tunnel using deep belief network

Evaluating the adaptability of cantilever boring machine(CBM) through in-depth excavation and analysis of tunnel excavation data and rock mass parameters is the premise of mechanical design and efficient excavation in the field of underground space engineering.This paper presented a case study of tunnelling performance prediction method of CBM in sedimentary hard-rock tunnel of Karst landform type by using tunneling data and surrounding rock parameters.The uniaxial compressive strength(UCS),rock integrity factor(Kv),basic quality index([BQ]),rock quality index RQD,brazilian tensile strength(BTS) and brittleness index(BI) were introduced to construct a performance prediction database based on the hard-rock tunnel of Guiyang Metro Line 1 and Line 3,and then established the performance prediction model of cantilever boring machine.Then the deep belief network(DBN) was introduced into the performance prediction model,and the reliability of performance prediction model was verified by combining with engineering data.The study showed that the influence degree of surrounding rock parameters on the tunneling performance of the cantilever boring machine is UCS > [BQ] > BTS >RQD > Kv > BI.The performance prediction model shows that the instantaneous cutting rate(ICR) has a good correlation with the surrounding rock parameters,and the predicting model accuracy is related to the reliability of construction data.The prediction of limestone and dolomite sections of Line 3 based on the DBN performance prediction model shows that the measured ICR and predicted ICR is consistent and the built performance prediction model is reliable.The research results have theoretical reference significance for the applicability analysis and mechanical selection of cantilever boring machine for hard rock tunnel.

Vibrations induced by tunnel boring machine in urban areas: In situ measurements and methodology of analysis

Excavation with tunnel boring machine(TBM)can generate vibrations,causing damages to neighbouring buildings and disturbing the residents or the equipment.This problem is particularly challenging in urban areas,where TBMs are increasingly large in diameter and shallow in depth.In response to this problem,four experimental campaigns were carried out in different geotechnical contexts in France.The vibration measurements were acquired on the surface and inside the TBMs.These measurements are also complemented by few data in the literature.An original methodology of signal processing is pro-posed to characterize the amplitude of the particle velocities,as well as the frequency content of the signals to highlight the most energetic bands.The levels of vibrations are also compared with the thresholds existing in various European regulations concerning the impact on neighbouring structures and the disturbance to local residents.

开挖补偿法防控深部地下岩爆灾害——引汉济渭工程秦岭输水隧洞案例分析

Rockburst disasters occur frequently during deep underground excavation,yet traditional concepts and methods can hardly meet the requirements for support under high geo-stress conditions.Consequently,rockburst control remains challenging in the engineering field.In this study,the mechanism of excavation-induced rockburst was briefly described,and it was proposed to apply the excavation compensation method(ECM)to rockburst control.Moreover,a field test was carried out on the Qinling Water Conveyance Tunnel.The following beneficial findings were obtained:Excavation leads to changes in the engineering stress state of surrounding rock and results in the generation of excess energy DE,which is the fundamental cause of rockburst.The ECM,which aims to offset the deep excavation effect and lower the risk of rockburst,is an active support strategy based on high pre-stress compensation.The new negative Poisson’s ratio(NPR)bolt developed has the mechanical characteristics of high strength,high toughness,and impact resistance,serving as the material basis for the ECM.The field test results reveal that the ECM and the NPR bolt succeed in controlling rockburst disasters effectively.The research results are expected to provide guidance for rockburst support in deep underground projects such as Sichuan-Xizang Railway.

Hydrodynamic Characteristics of Undular Tidal Bores in the Qiantang River Based on Field Observations

Understanding the undular tidal bores in the Qiantang River is essential for effective river management and maintenance.While breaking tidal bores have been studied extensively, reports on undular tidal bores in the Qiantang Riverremain limited. Furthermore, observed data on undular tidal bores fulfilling the requirements of short measurementtime intervals, and spring, medium, and neap tide coverage, and providing detailed data for the global vertical stratificationof flow velocity are quite limited. Based on field observations at Qige in the Qiantang estuary, we analyzedthe characteristics of undular tidal bores. The results showed that the flooding amplitude (a) of the first wave isalways larger than its ebbing amplitude (b). Moreover, the vertical distribution of the maximum flood velocity exhibitesthree shapes, influenced by the tidal range, while that of the maximum ebb velocity exhibites a single shape. Duringthe initial phase of the flood tide in the spring and medium tides, the upper water body experiences multiple oscillatingchanges along the flow direction, corresponding to the alternating process of the crest and trough of the tide levelupon the arrival of the tidal bore. The tidal range is a crucial parameter in tidal bore hydrodynamics. By establishingthe relationship between hydrodynamic parameters and tidal range, other hydrodynamic parameters, such as the tidalbore height, maximum flood depth–averaged velocity, maximum flood stratified velocity at the measurement points,and duration of the flood tide current, can be effectively predicted, thereby providing an important reference for rivermanagement and maintenance.

An Optimized System of Random Forest Model by Global Harmony Search with Generalized Opposition-Based Learning for Forecasting TBM Advance Rate

As massive underground projects have become popular in dense urban cities,a problem has arisen:which model predicts the best for Tunnel Boring Machine(TBM)performance in these tunneling projects?However,performance level of TBMs in complex geological conditions is still a great challenge for practitioners and researchers.On the other hand,a reliable and accurate prediction of TBM performance is essential to planning an applicable tunnel construction schedule.The performance of TBM is very difficult to estimate due to various geotechnical and geological factors and machine specifications.The previously-proposed intelligent techniques in this field are mostly based on a single or base model with a low level of accuracy.Hence,this study aims to introduce a hybrid randomforest(RF)technique optimized by global harmony search with generalized oppositionbased learning(GOGHS)for forecasting TBM advance rate(AR).Optimizing the RF hyper-parameters in terms of,e.g.,tree number and maximum tree depth is the main objective of using the GOGHS-RF model.In the modelling of this study,a comprehensive databasewith themost influential parameters onTBMtogetherwithTBM AR were used as input and output variables,respectively.To examine the capability and power of the GOGHSRF model,three more hybrid models of particle swarm optimization-RF,genetic algorithm-RF and artificial bee colony-RF were also constructed to forecast TBM AR.Evaluation of the developed models was performed by calculating several performance indices,including determination coefficient(R2),root-mean-square-error(RMSE),and mean-absolute-percentage-error(MAPE).The results showed that theGOGHS-RF is a more accurate technique for estimatingTBMAR compared to the other applied models.The newly-developedGOGHS-RFmodel enjoyed R2=0.9937 and 0.9844,respectively,for train and test stages,which are higher than a pre-developed RF.Also,the importance of the input parameters was interpreted through the SHapley Additive exPlanations(SHAP)method,and it was found that thrust force per cutter is the most important variable on TBMAR.The GOGHS-RF model can be used in mechanized tunnel projects for predicting and checking performance.

A performance-based hybrid deep learning model for predicting TBM advance rate using Attention-ResNet-LSTM

The technology of tunnel boring machine(TBM)has been widely applied for underground construction worldwide;however,how to ensure the TBM tunneling process safe and efficient remains a major concern.Advance rate is a key parameter of TBM operation and reflects the TBM-ground interaction,for which a reliable prediction helps optimize the TBM performance.Here,we develop a hybrid neural network model,called Attention-ResNet-LSTM,for accurate prediction of the TBM advance rate.A database including geological properties and TBM operational parameters from the Yangtze River Natural Gas Pipeline Project is used to train and test this deep learning model.The evolutionary polynomial regression method is adopted to aid the selection of input parameters.The results of numerical exper-iments show that our Attention-ResNet-LSTM model outperforms other commonly-used intelligent models with a lower root mean square error and a lower mean absolute percentage error.Further,parametric analyses are conducted to explore the effects of the sequence length of historical data and the model architecture on the prediction accuracy.A correlation analysis between the input and output parameters is also implemented to provide guidance for adjusting relevant TBM operational parameters.The performance of our hybrid intelligent model is demonstrated in a case study of TBM tunneling through a complex ground with variable strata.Finally,data collected from the Baimang River Tunnel Project in Shenzhen of China are used to further test the generalization of our model.The results indicate that,compared to the conventional ResNet-LSTM model,our model has a better predictive capability for scenarios with unknown datasets due to its self-adaptive characteristic.

Research on the Dynamic Model of Spindle Rotation Induced Error Compensation System of Boring and its Simulation

In this paper we address the dynamics of compensation cutting process from both Laplace s frequency domain and the time domain of the first time, using the two computer aided analyzing softwares: MATLAB and SIMULINK. Theoretical analysis and simulation experiments firstly show that not only the systematical stiffness of workpiece, spindle and tools, but also the regenerated coefficient affects the compensation displacement effect. The results show that the SREC is practicable in reality to decease the spindle induced errors in many engineering applications such as hard boring through simulation and the preliminary experiment results.

Design Theory of Full Face Rock Tunnel Boring Machine Transition Cutter Edge Angle and Its Application

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.

Wear Analysis of Disc Cutters of Full Face Rock Tunnel Boring Machine

Wear is a major factor of disc cutters’ failure. No current theory offers a standard for the prediction of disc cutter wear yet. In the field the wear prediction method commonly used is based on the excavation length of tunnel boring machine（TBM） to predict the disc cutter wear and its wear law, considering the location number of each disc cutter on the cutterhead（radius for installation）; in theory, there is a prediction method of using arc wear coefficient. However, the preceding two methods have their own errors, with their accuracy being 40% or so and largely relying on the technicians’ experience. Therefore, radial wear coefficient, axial wear coefficient and trajectory wear coefficient are defined on the basis of the operating characteristics of TBM. With reference to the installation and characteristics of disc cutters, those coefficients are modified according to penetration, which gives rise to the presentation of comprehensive axial wear coefficient, comprehensive radial wear coefficient and comprehensive trajectory wear coefficient. Calculation and determination of wear coefficients are made with consideration of data from a segment of TBM project（excavation length 173 m）. The resulting wear coefficient values, after modification, are adopted to predict the disc cutter wear in the follow-up segment of the TBM project（excavation length of 5621 m）. The prediction results show that the disc cutter wear predicted with comprehensive radial wear coefficient and comprehensive trajectory wear coefficient are not only accurate（accuracy 16.12%） but also highly congruous, whereas there is a larger deviation in the prediction with comprehensive axial wear coefficient（accuracy 41%, which is in agreement with the prediction of disc cutters’ life in the field）. This paper puts forth a new method concerning prediction of life span and wear of TBM disc cutters as well as timing for replacing disc cutters.

Theoretical prediction of wear of disc cutters in tunnel boring machine and its application

Predicting the cutter consumption and the exact time to replace the worn-out cutters in tunneling projects constructed with tunnel boring machine(TBM) is always a challenging issue. In this paper, we focus on the analyses of cutter motion in the rock breaking process and trajectory of rock breaking point on the cutter edge in rocks. The analytical expressions of the length of face along which the breaking point moves and the length of spiral trajectory of the maximum penetration point are derived. Through observation of rock breaking process of disc cutters as well as analysis of disc rock interaction, the following concepts are proposed: the arc length theory of predicting wear extent of inner and center cutters, and the spiral theory of predicting wear extent of gage and transition cutters. Data obtained from5621 m-long Qinling tunnel reveal that among 39 disc cutters, the relative errors between cumulatively predicted and measured wear values for nine cutters are larger than 20%, while approximately 76.9% of total cutters have the relative errors less than 20%. The proposed method could offer a new attempt to predict the disc cutter's wear extent and changing time.

Excavation of underground research laboratory ramp in granite using tunnel boring machine: Feasibility study

Underground research laboratory(URL)plays an important role in safe disposal of high-level radioactive waste(HLW).At present,the Xinchang site,located in Gansu Province of China,has been selected as the final site for China’s first URL,named Beishan URL.For this,a preliminary design of the Beishan URL has been proposed,including one spiral ramp,three shafts and two experimental levels.With advantages of fast advancing and limited disturbance to surrounding rock mass,the tunnel boring machine(TBM)method could be one of the excavation methods considered for the URL ramp.This paper introduces the feasibility study on using TBM to excavation of the Beishan URL ramp.The technical challenges for using TBM in Beishan URL are identified on the base of geological condition and specific layout of the spiral ramp.Then,the technical feasibility study on the specific issues,i.e.extremely hard rock mass,high abrasiveness,TBM operation,muck transportation,water drainage and material transportation,is investigated.This study demonstrates that TBM technology is a feasible method for the Beishan URL excavation.The results can also provide a reference for the design and construction of HLW disposal engineering in similar geological conditions.2020 Institute of Rock and Soil Mechanics,Chinese Academy of Sciences.Production and hosting by Elsevier B.V.This is an open access article under the CC BY-NC-ND license(http://creativecommons.org/licenses/by-nc-nd/4.0/).

Load-sharing Characteristic of Multiple Pinions Driving in Tunneling Boring Machine

The failure of the key parts, such as gears, in cutter head driving system of tunneling boring machine has not been properly solved under the interaction of driving motors asynchronously and wave tunneling torque load. A dynamic model of multi-gear driving system is established considering the inertia effects of driving mechanism and cutter head as well as the bending-torsional coupling. By taking into account the nonlinear coupling factors between ring gear and multiple pinions, the influence for meshing angle by bending-torsional coupling and the dynamic load-sharing characteristic of multiple pinions driving are analyzed. Load-sharing coefficients at different rotating cutter head speeds and input torques are presented. Numerical results indicate that the load-sharing coefficients can reach up to 1.2-1.3. A simulated experimental platform of the multiple pinions driving is carried out and the torque distributions under the step load in driving shaft of pinions are measured. The imbalance of torque distribution of pinions is verified and the load-sharing coefficients in each pinion can reach 1.262. The results of simulation and test are similar, which shows the correctness of theoretical model. A loop coupling control method is put forward based on current torque master slave control method. The imbalance of the multiple pinions driving in cutter head driving system of tunneling boring machine can be greatly decreased and the load-sharing coefficients can be reduced to 1.051 by using the loop coupling control method. The proposed research provides an effective solution to the imbalance of torque distribution and synchronous control method for multiple pinions driving of TBM.

Hybrid ensemble soft computing approach for predicting penetration rate of tunnel boring machine in a rock environment

This study implements a hybrid ensemble machine learning method for forecasting the rate of penetration(ROP) of tunnel boring machine(TBM),which is becoming a prerequisite for reliable cost assessment and project scheduling in tunnelling and underground projects in a rock environment.For this purpose,a sum of 185 datasets was collected from the literature and used to predict the ROP of TBM.Initially,the main dataset was utilised to construct and validate four conventional soft computing(CSC)models,i.e.minimax probability machine regression,relevance vector machine,extreme learning machine,and functional network.Consequently,the estimated outputs of CSC models were united and trained using an artificial neural network(ANN) to construct a hybrid ensemble model(HENSM).The outcomes of the proposed HENSM are superior to other CSC models employed in this study.Based on the experimental results(training RMSE=0.0283 and testing RMSE=0.0418),the newly proposed HENSM is potential to assist engineers in predicting ROP of TBM in the design phase of tunnelling and underground projects.

Novel mechanism for boring non-cylinder piston pinhole based on giant magnetostrictive materials

To bear more loads for heavy truck pistons, the shape of heavy truck piston pinhole is often designed as noncylinder form. Current methods cannot meet the needs for precision machining on non-cylinder piston pinhole （NCPPH）. A novel mechanism based on giant magnetostrictive materials （GMM） is presented. New models are established for the servo mechanism, GMM, and magnetizing force of the control solenoid to characterize the relationship between the control current of the solenoid and the displacement of the giant magnetostrictive actuator （GMA）. Experiments show that the novel mechanism can meet the needs to perform fine machining on NCPPH effectively.

Modeling and simulation of bullet-barrel interaction process for the damaged gun barrel

In this paper,the influences of bore damage on the bullet-barrel interaction process and the mechanism of how bore damage results in the end of a machine gun barrel’s service life were studied,which had seldom been paid attention to in the past several decades.A novel finite element mesh generation method for the damaged barrel and a new transient coupled thermo-mechanical finite element(FE)model,which were based on the damage data obtained through barrel life tests,were developed to simulate the interior ballistics process of a coupled bullet-barrel system.Additionally,user subroutine VUAMP was developed in the FE model in order to take the bullet base pressure brought by propellant gas into account.Good consistency between the simulation results and the experimental results verified the preciseness of the proposed mesh generation method and the FE model.The simulation results show that the increase of bullet’s initial disturbance at the muzzle and the variation of its surface morphology caused by bore damage are primarily responsible for the life end of this 12.7 mm machine gun barrel.

Tunnel boring machine vibration-based deep learning for the ground identification of working faces

Tunnel boring machine(TBM) vibration induced by cutting complex ground contains essential information that can help engineers evaluate the interaction between a cutterhead and the ground itself.In this study,deep recurrent neural networks(RNNs) and convolutional neural networks(CNNs) were used for vibration-based working face ground identification.First,field monitoring was conducted to obtain the TBM vibration data when tunneling in changing geological conditions,including mixed-face,homogeneous,and transmission ground.Next,RNNs and CNNs were utilized to develop vibration-based prediction models,which were then validated using the testing dataset.The accuracy of the long short-term memory(LSTM) and bidirectional LSTM(Bi-LSTM) models was approximately 70% with raw data;however,with instantaneous frequency transmission,the accuracy increased to approximately 80%.Two types of deep CNNs,GoogLeNet and ResNet,were trained and tested with time-frequency scalar diagrams from continuous wavelet transformation.The CNN models,with an accuracy greater than 96%,performed significantly better than the RNN models.The ResNet-18,with an accuracy of 98.28%,performed the best.When the sample length was set as the cutterhead rotation period,the deep CNN and RNN models achieved the highest accuracy while the proposed deep CNN model simultaneously achieved high prediction accuracy and feedback efficiency.The proposed model could promptly identify the ground conditions at the working face without stopping the normal tunneling process,and the TBM working parameters could be adjusted and optimized in a timely manner based on the predicted results.

A real-time prediction method for tunnel boring machine cutter-head torque using bidirectional long short-term memory networks optimized by multi-algorithm

Based on data from the Jilin Water Diversion Tunnels from the Songhua River(China),an improved and real-time prediction method optimized by multi-algorithm for tunnel boring machine(TBM)cutter-head torque is presented.Firstly,a function excluding invalid and abnormal data is established to distinguish TBM operating state,and a feature selection method based on the SelectKBest algorithm is proposed.Accordingly,ten features that are most closely related to the cutter-head torque are selected as input variables,which,in descending order of influence,include the sum of motor torque,cutter-head power,sum of motor power,sum of motor current,advance rate,cutter-head pressure,total thrust force,penetration rate,cutter-head rotational velocity,and field penetration index.Secondly,a real-time cutterhead torque prediction model’s structure is developed,based on the bidirectional long short-term memory(BLSTM)network integrating the dropout algorithm to prevent overfitting.Then,an algorithm to optimize hyperparameters of model based on Bayesian and cross-validation is proposed.Early stopping and checkpoint algorithms are integrated to optimize the training process.Finally,a BLSTMbased real-time cutter-head torque prediction model is developed,which fully utilizes the previous time-series tunneling information.The mean absolute percentage error(MAPE)of the model in the verification section is 7.3%,implying that the presented model is suitable for real-time cutter-head torque prediction.Furthermore,an incremental learning method based on the above base model is introduced to improve the adaptability of the model during the TBM tunneling.Comparison of the prediction performance between the base and incremental learning models in the same tunneling section shows that:(1)the MAPE of the predicted results of the BLSTM-based real-time cutter-head torque prediction model remains below 10%,and both the coefficient of determination(R^(2))and correlation coefficient(r)between measured and predicted values exceed 0.95;and(2)the incremental learning method is suitable for realtime cutter-head torque prediction and can effectively improve the prediction accuracy and generalization capacity of the model during the excavation process.