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...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.展开更多
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...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.展开更多
为研究三模式掘进机使用TBM模式在全断面岩层中的施工技术,以广州地铁7号线二期萝岗站—水西站盾构区间工程为研究背景,分别从出渣方式、掘进参数控制、刀具管理和稳定器应用4个方面对三模式掘进机TBM模式施工技术进行总结。结果表明:1...为研究三模式掘进机使用TBM模式在全断面岩层中的施工技术,以广州地铁7号线二期萝岗站—水西站盾构区间工程为研究背景,分别从出渣方式、掘进参数控制、刀具管理和稳定器应用4个方面对三模式掘进机TBM模式施工技术进行总结。结果表明:1)本工程中三模式掘进机使用镶齿滚刀施工,相对光面滚刀的消耗更少,刀盘转矩更低;2)三模式掘进机TBM模式采用泥浆循环和螺旋输送机双通道出渣,可显著降低泥浆管堵塞的概率,提高出渣效率;3)三模式掘进机在前盾、中盾安装稳定器和撑靴,可保证全断面硬岩地层中掘进盾体不发生滚动,同时增强盾体稳定性;4)在全断面岩层中采用三模式掘进机TBM模式开挖隧道,刀盘转速为3.0 r/min,总推力约15000 k N,转矩可控制在1300 k N·m,推进速度为8~12 mm/min。展开更多
基金supported by National Natural Science Foundation of China (Grant No. 51075147)
文摘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.
基金Supported by National Natural Science Foundation of China (Grant No.51075147)National Hi-tech Research and Development Program of China (863 Program,Grant No.2012AA041803)
文摘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.
文摘为研究三模式掘进机使用TBM模式在全断面岩层中的施工技术,以广州地铁7号线二期萝岗站—水西站盾构区间工程为研究背景,分别从出渣方式、掘进参数控制、刀具管理和稳定器应用4个方面对三模式掘进机TBM模式施工技术进行总结。结果表明:1)本工程中三模式掘进机使用镶齿滚刀施工,相对光面滚刀的消耗更少,刀盘转矩更低;2)三模式掘进机TBM模式采用泥浆循环和螺旋输送机双通道出渣,可显著降低泥浆管堵塞的概率,提高出渣效率;3)三模式掘进机在前盾、中盾安装稳定器和撑靴,可保证全断面硬岩地层中掘进盾体不发生滚动,同时增强盾体稳定性;4)在全断面岩层中采用三模式掘进机TBM模式开挖隧道,刀盘转速为3.0 r/min,总推力约15000 k N,转矩可控制在1300 k N·m,推进速度为8~12 mm/min。
