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
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 anal...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.展开更多
In tunnel construction with tunnel boring machines(TBMs),accurate prediction of the remaining useful life(RUL)of disc cutters is critical for timely maintenance and replacement to avoid delays and cost overruns.This p...In tunnel construction with tunnel boring machines(TBMs),accurate prediction of the remaining useful life(RUL)of disc cutters is critical for timely maintenance and replacement to avoid delays and cost overruns.This paper introduces a novel hybrid model,integrating fundamental and data-driven approaches,to enhance wear prediction of TBM disc cutters and enable accurate RUL estimation.The fundamental model is improved by incorporating composite wear mechanisms and load estimation techniques,showcasing superior prediction accuracy compared to single-mechanism models.Additionally,the hybrid model innovatively incorporates a data-driven supplementary residual term into the improved fundamental model,leading to a high-performance wear prediction model.Using actual field data from a highway tunnel project in Shenzhen,the performance of the hybrid model is rigorously tested and compared with pure fundamental and data-driven models.The hybrid model outperforms the other models,achieving the highest accuracy in predicting TBM disc cutter wear(mean absolute error(MAE)=0.53,root mean square error(RMSE)=0.64).Furthermore,this study thoroughly analyzes the hybrid model’s generalization capability,revealing significant impacts of geological conditions on prediction accuracy.The model’s generalization capability is also improved by expanding and updating the data sets.The RUL estimation results provided by the hybrid model are straightforward and effective,making it a valuable tool by which construction staff can monitor TBM disc cutters.展开更多
In the actual service process of the tunnel boring machine(TBM)cutter head,the fatigue failure of the disc body is serious.Aimed at the problem of premature failure of cutter head due to the extreme service environmen...In the actual service process of the tunnel boring machine(TBM)cutter head,the fatigue failure of the disc body is serious.Aimed at the problem of premature failure of cutter head due to the extreme service environment and complicated structure of the TBM cutter head,the previous TBM cutter head failure data are combined to establish a method for calculating the space crack growth in this paper.Based on the structure of the TBM cutter head itself,the law of the shape and parameters of the stiffened panels on the crack propagation resistance is studied to further present the method of anti-damage and anti-crack for the TBM cutter head.The results illustrate that the basis and methods for the structural design of the TBM cutter head are put forward.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.
基金supported by the National Natural Science Foundation of China(Grant No.51475163)the National Hightech R&D Program of China(Grant No.2012AA041803)
文摘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.
基金This work received partial support from the National Key R&D Program of China(Nos.2018YFB1702503 and 2020YFF0218004)the National Natural Science Foundation of China(Grant No.52105074)the Open Project of State Key Laboratory of Shield Machine and Boring Technology(No.SKLST-2021-K02).
文摘In tunnel construction with tunnel boring machines(TBMs),accurate prediction of the remaining useful life(RUL)of disc cutters is critical for timely maintenance and replacement to avoid delays and cost overruns.This paper introduces a novel hybrid model,integrating fundamental and data-driven approaches,to enhance wear prediction of TBM disc cutters and enable accurate RUL estimation.The fundamental model is improved by incorporating composite wear mechanisms and load estimation techniques,showcasing superior prediction accuracy compared to single-mechanism models.Additionally,the hybrid model innovatively incorporates a data-driven supplementary residual term into the improved fundamental model,leading to a high-performance wear prediction model.Using actual field data from a highway tunnel project in Shenzhen,the performance of the hybrid model is rigorously tested and compared with pure fundamental and data-driven models.The hybrid model outperforms the other models,achieving the highest accuracy in predicting TBM disc cutter wear(mean absolute error(MAE)=0.53,root mean square error(RMSE)=0.64).Furthermore,this study thoroughly analyzes the hybrid model’s generalization capability,revealing significant impacts of geological conditions on prediction accuracy.The model’s generalization capability is also improved by expanding and updating the data sets.The RUL estimation results provided by the hybrid model are straightforward and effective,making it a valuable tool by which construction staff can monitor TBM disc cutters.
基金Scientific Research Project of Education Department of Liaoning Province(No.JDL2020028)。
文摘In the actual service process of the tunnel boring machine(TBM)cutter head,the fatigue failure of the disc body is serious.Aimed at the problem of premature failure of cutter head due to the extreme service environment and complicated structure of the TBM cutter head,the previous TBM cutter head failure data are combined to establish a method for calculating the space crack growth in this paper.Based on the structure of the TBM cutter head itself,the law of the shape and parameters of the stiffened panels on the crack propagation resistance is studied to further present the method of anti-damage and anti-crack for the TBM cutter head.The results illustrate that the basis and methods for the structural design of the TBM cutter head are put forward.
