Form milling cutter is built-for-purpose cutter which process the form surface, for example, usually process male and female circular arc face and form trench and so on. From the traditional concept, form milling cutt...Form milling cutter is built-for-purpose cutter which process the form surface, for example, usually process male and female circular arc face and form trench and so on. From the traditional concept, form milling cutter is divided into pointed tooth and relieving follow its structure. Relieving shaped cutter is more convenient than pointed tooth milling cutter, because only its rake face is needed to grind after it turn into blunting, so the current books which are used in college almost select relieving shaped cutter in order to introduce how to design the form milling cutter.The curve of the back of tooth of relieving cutter is the transversal which is formed by the rear face of tooth in the end cut plane of the milling cutter. In the past, because of the limit of the manufacturing technology, the curve of the back of tooth is often selected Archimedes’ curve, in order that the shovel-nose tool acquire the uniform motion when the cutter shovel the back, in other word, the rear face of the milling cutter rotate its axis by the new cutting lip, in the same time, it move uniformly to the axis in order to form the surface. Although this curve of the back of tooth meet the fixedness of the form of blade around grinding the cutter, the rear angle of the dot of the cutting lip don’t keep fixedness. With the development of the modern manufacturing technology, the unmanageable problem of many complex curves is already easily solved. So it is need to study the optimum profile of the curve of the back of tooth in theory, and study the design theory of the relieving shaped cutter under the condition of new manufacture, in order to ensure that the rear angle of the dot of the cutting lip keep fixedness after the relieving shaped cutter is grinded. The paper derive the curve profile of tooth of the form cutter and the modifier calculation formula of the profile of the cutter edge from the definition of the rear angle of the cutter, which establish the foundation for the precision design and manufacture of other form cutter.展开更多
Cutterhead loads are the key mechanical parameters for the strength design of the full face hard rock tunnel boring machine(TBM).Due to the brittle rock-breaking mechanism,the excavation loads acting on cutters fluctu...Cutterhead loads are the key mechanical parameters for the strength design of the full face hard rock tunnel boring machine(TBM).Due to the brittle rock-breaking mechanism,the excavation loads acting on cutters fluctuate strongly and show some randomness.The conventional method that using combinations of some special static loads to perform the strength design of TBM cutterhead may lead to strength failure during working practice.In this paper,a three-dimensional finite element model for coupled Cutterhead–Rock is developed to determine the cutterhead loads.Then the distribution characteristics and the influence factors of cutterhead loads are analyzed based on the numerical results.It is found that,as time changes,the normal and tangential forces acting on cutters and the total torque acting on the cutterhead approximately distribute log normally,while the total thrusts acting on the cutterhead approximately show a normal distribution.Furthermore,the statistical average values of cutterhead loads are proportional to the uniaxial compressive strength(UCS)of cutting rocks.The values also change with the penetration and the diameter of cutterhead following a power function.Based on these findings,we propose a three-parameter model for the mean of cutterhead loads and a method of generating the random cutter forces.Then the strength properties of a typical cutterhead are analyzed in detail using loads generated by the new method.The optimized cutterhead has been successfully applied in engineering.The method in this paper may provide a useful reference for the strength design of TBM cutterhead.展开更多
Attempts to minimize energy consumption of a tunnel boring machine disc cutter during the process of fragmentation have largely focused on optimizing disc- cutter spacing, as determined by the minimum specific energy ...Attempts to minimize energy consumption of a tunnel boring machine disc cutter during the process of fragmentation have largely focused on optimizing disc- cutter spacing, as determined by the minimum specific energy required for fragmentation; however, indentation tests showed that rock deforms plastically beneath the cutters. Equations for thrust were developed for both the traditional, popularly employed disc cutter and anew design based on three-dimensional theory. The respective energy consumption for penetration, rolling, and side-slip fragmentations were obtained. A change in disc-cutter fragmentation angles resulted in a change in the nature of the interaction between the cutter and rock, which lowered the specific energy of fragmentation. During actual field excavations to the same penetration length, the combined energy consumption for fragmentation using the newly designed cutters was 15% lower than that when using the traditional design. This paper presents a theory for energy saving in tunnel boring machines. Investigation results showed that the disc cutters designed using this theory were more durable than traditional designs, and effectively lowered the energy consumption.展开更多
Full face rock tunnel boring machine（TBM） has been widely used in hard rock tunnels, however, there are few published theory about cutter-head design, and the design criteria of cutter-head under complex geological ...Full face rock tunnel boring machine（TBM） has been widely used in hard rock tunnels, however, there are few published theory about cutter-head design, and the design criteria of cutter-head under complex geological is not clear yet. To deal with the complex relationship among geological parameters, cutter parameters, and operating parameters during tunneling processes, a cutter-head load model is established by using CSM（Colorado school of mines） prediction model. Force distribution on cutter-head under a certain geology is calculated with the new established load model, and result shows that inner cutters bear more force than outer cutters, combining with disc cutters abrasion; a general principle of disc cutters＇ layout design is proposed. Within the model, the relationship among rock uniaxial compressive strength（UCS）, penetration and thrust on cutter-head are analyzed, and the results shows that with increasing penetration, cutter thrust increases, but the growth rate slows and higher penetration makes lower special energy（SE）. Finally, a fitting mathematical model of ZT（ratio of cutter-head torque and thrust） and penetration is established, and verified by TB880 E, which can be used to direct how to set thrust and torque on cutter-head. When penetration is small, the cutter-head thrust is the main limiting factor in tunneling; when the penetration is large, cutter-head torque is the major limiting factor in tunneling. Based on the new cutter-head load model, thrust and torque characteristics of TBM further are researched and a new way for cutter-head layout design and TBM tunneling operations is proposed.展开更多
文摘Form milling cutter is built-for-purpose cutter which process the form surface, for example, usually process male and female circular arc face and form trench and so on. From the traditional concept, form milling cutter is divided into pointed tooth and relieving follow its structure. Relieving shaped cutter is more convenient than pointed tooth milling cutter, because only its rake face is needed to grind after it turn into blunting, so the current books which are used in college almost select relieving shaped cutter in order to introduce how to design the form milling cutter.The curve of the back of tooth of relieving cutter is the transversal which is formed by the rear face of tooth in the end cut plane of the milling cutter. In the past, because of the limit of the manufacturing technology, the curve of the back of tooth is often selected Archimedes’ curve, in order that the shovel-nose tool acquire the uniform motion when the cutter shovel the back, in other word, the rear face of the milling cutter rotate its axis by the new cutting lip, in the same time, it move uniformly to the axis in order to form the surface. Although this curve of the back of tooth meet the fixedness of the form of blade around grinding the cutter, the rear angle of the dot of the cutting lip don’t keep fixedness. With the development of the modern manufacturing technology, the unmanageable problem of many complex curves is already easily solved. So it is need to study the optimum profile of the curve of the back of tooth in theory, and study the design theory of the relieving shaped cutter under the condition of new manufacture, in order to ensure that the rear angle of the dot of the cutting lip keep fixedness after the relieving shaped cutter is grinded. The paper derive the curve profile of tooth of the form cutter and the modifier calculation formula of the profile of the cutter edge from the definition of the rear angle of the cutter, which establish the foundation for the precision design and manufacture of other form cutter.
基金Supported by National Basic Research Program of China(973 Program,Grant No.2013CB035042)the National Natural Science Foundation of China(Grant No.11672202)
文摘Cutterhead loads are the key mechanical parameters for the strength design of the full face hard rock tunnel boring machine(TBM).Due to the brittle rock-breaking mechanism,the excavation loads acting on cutters fluctuate strongly and show some randomness.The conventional method that using combinations of some special static loads to perform the strength design of TBM cutterhead may lead to strength failure during working practice.In this paper,a three-dimensional finite element model for coupled Cutterhead–Rock is developed to determine the cutterhead loads.Then the distribution characteristics and the influence factors of cutterhead loads are analyzed based on the numerical results.It is found that,as time changes,the normal and tangential forces acting on cutters and the total torque acting on the cutterhead approximately distribute log normally,while the total thrusts acting on the cutterhead approximately show a normal distribution.Furthermore,the statistical average values of cutterhead loads are proportional to the uniaxial compressive strength(UCS)of cutting rocks.The values also change with the penetration and the diameter of cutterhead following a power function.Based on these findings,we propose a three-parameter model for the mean of cutterhead loads and a method of generating the random cutter forces.Then the strength properties of a typical cutterhead are analyzed in detail using loads generated by the new method.The optimized cutterhead has been successfully applied in engineering.The method in this paper may provide a useful reference for the strength design of TBM cutterhead.
基金Supported by National Natural Science Foundation of China(Grant No.51475163)National Hi-tech Research and Development Program of China(863 Program,Grant No.2012AA041803)
文摘Attempts to minimize energy consumption of a tunnel boring machine disc cutter during the process of fragmentation have largely focused on optimizing disc- cutter spacing, as determined by the minimum specific energy required for fragmentation; however, indentation tests showed that rock deforms plastically beneath the cutters. Equations for thrust were developed for both the traditional, popularly employed disc cutter and anew design based on three-dimensional theory. The respective energy consumption for penetration, rolling, and side-slip fragmentations were obtained. A change in disc-cutter fragmentation angles resulted in a change in the nature of the interaction between the cutter and rock, which lowered the specific energy of fragmentation. During actual field excavations to the same penetration length, the combined energy consumption for fragmentation using the newly designed cutters was 15% lower than that when using the traditional design. This paper presents a theory for energy saving in tunnel boring machines. Investigation results showed that the disc cutters designed using this theory were more durable than traditional designs, and effectively lowered the energy consumption.
基金Supported by National Natural Science Foundation of China(Grant No.51275339)National Basic Research Program of China(973 Program,Grant No.2013CB035402)
文摘Full face rock tunnel boring machine（TBM） has been widely used in hard rock tunnels, however, there are few published theory about cutter-head design, and the design criteria of cutter-head under complex geological is not clear yet. To deal with the complex relationship among geological parameters, cutter parameters, and operating parameters during tunneling processes, a cutter-head load model is established by using CSM（Colorado school of mines） prediction model. Force distribution on cutter-head under a certain geology is calculated with the new established load model, and result shows that inner cutters bear more force than outer cutters, combining with disc cutters abrasion; a general principle of disc cutters＇ layout design is proposed. Within the model, the relationship among rock uniaxial compressive strength（UCS）, penetration and thrust on cutter-head are analyzed, and the results shows that with increasing penetration, cutter thrust increases, but the growth rate slows and higher penetration makes lower special energy（SE）. Finally, a fitting mathematical model of ZT（ratio of cutter-head torque and thrust） and penetration is established, and verified by TB880 E, which can be used to direct how to set thrust and torque on cutter-head. When penetration is small, the cutter-head thrust is the main limiting factor in tunneling; when the penetration is large, cutter-head torque is the major limiting factor in tunneling. Based on the new cutter-head load model, thrust and torque characteristics of TBM further are researched and a new way for cutter-head layout design and TBM tunneling operations is proposed.
