海底复杂地层超大直径盾构刀盘设计与优化
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摘要
为解决海底复杂地层超大直径盾构刀盘设计中面临的刀间距布置、刀盘结构分析、刀盘功能优化等难题,基于某海湾隧道工程地质、水文特点,对盾构穿越海域段全断面软土层、孤石侵入的软土地层、基岩突起地层等工况开展分析。首先,开展室内不同刀间距破岩实验确定中心区域间距并提出刀盘刀具的总体布置方案;其次,采用数值计算对刀盘结构进行静力学和模态分析,结构的最大应力为190 MPa,最大变形为6.2 mm,前6阶频率为26.6～42.9 Hz,固有频率避开了工作频率;最后,考虑工程特点进行集中控制分布式冲刷系统、刀具运行状态监测及耐磨保护措施的刀盘功能优化。工程应用表明,刀盘结构强度、刚度满足要求,刀间距设计合理,刀盘优化措施提升了盾构在淤泥及海底软硬不均地层的适应性,可为类似海底复杂地层盾构选型及设计提供一定的参考。
The issues such as cutter spacing arrangement, cutterhead structure analysis and cutterhead function optimization in the design of super-large diameter shield cutterhead boring in submarine complex strata are very important. Hence, the working conditions of a shield bay tunnel crossing full-face soft strata, soft strata intruded by boulders and bedrock protruding strata are analyzed in detail based on geological and hydrological conditions of the project. Firstly, the indoor rock breaking tests with different cutter spacings are carried out to determine the cutter spacing in the central area, and the general layout scheme of the cutterhead is proposed. And then the static and modal analysis of the cutterhead structure are carried out by numerical calculation, and the results show that the maximum structural stress reaches 190 MPa, the maximum deformation reaches 6.2 mm, the first six natural frequencies range from 26.6 Hz to 42.9 Hz, and the natural frequencies avoid the working frequencies. Finally, the cutterhead optimization methods, i.e. centralized control and distributed scouring system, cutter running condition monitoring and wear-resistant protection measures are put forward. The application results show that the cutter spacing is rational, the cutterhead structure can meet the requirements of strength and stiffness, and the cutterhead optimization methods can improve the adaptability of shield in silt and hard and soft strata. The results can provide reference for shield design and selection in similar projects in the future.
The issues such as cutter spacing arrangement, cutterhead structure analysis and cutterhead function optimization in the design of super-large diameter shield cutterhead boring in submarine complex strata are very important. Hence, the working conditions of a shield bay tunnel crossing full-face soft strata, soft strata intruded by boulders and bedrock protruding strata are analyzed in detail based on geological and hydrological conditions of the project. Firstly, the indoor rock breaking tests with different cutter spacings are carried out to determine the cutter spacing in the central area, and the general layout scheme of the cutterhead is proposed. And then the static and modal analysis of the cutterhead structure are carried out by numerical calculation, and the results show that the maximum structural stress reaches 190 MPa, the maximum deformation reaches 6.2 mm, the first six natural frequencies range from 26.6 Hz to 42.9 Hz, and the natural frequencies avoid the working frequencies. Finally, the cutterhead optimization methods, i.e. centralized control and distributed scouring system, cutter running condition monitoring and wear-resistant protection measures are put forward. The application results show that the cutter spacing is rational, the cutterhead structure can meet the requirements of strength and stiffness, and the cutterhead optimization methods can improve the adaptability of shield in silt and hard and soft strata. The results can provide reference for shield design and selection in similar projects in the future.
引文
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[11] 王凯,陈馈,孙振川,等.基于复合磨蚀试验台的滚刀磨损试验研究[J].隧道建设(中英文),2018,38(1):142.WANG Kai,CHEN Kui,SUN Zhenchuan,et al.Experimental study of disc cutter wear based on composite abrasion test platform[J].Tunnel Construction,2018,38(1):142.
[12] 王玮,李自贵,赵海峰,等.全断面掘进机综合试验机刀盘有限元分析[J].机械设计与制造,2013(6):137.WANG Wei,LI Zigui,ZHAO Haifeng,et al.Finite element analysis on the comprehensive testing machine of tunnel boring machine cutter head[J].Machinery Design & Manufacture,2013(6):137.
[13] 周阳宗,聂羽飞,李杰,等.某型复合盾构刀盘的有限元静动态特性分析与优化[J].现代隧道技术,2015,52(3):144.ZHOU Yangzong,NIE Yufei,LI Jie,et al.Static and dynamic FEM analyses and optimization of a mix-shield cutterhead[J].Modern Tunnelling Technology,2015,52(3):144.
[14] 王凯,张仕民.压裂车车架动态特性分析[J].科学技术与工程,2017,17(31):346.WANG Kai,ZHANG Shimin.Dynamic characteristics analysis of fracturing truck frame[J].Science Technology and Engineering,2017,17(31):346.
[15] 李东利,孙志洪,任德志,等.电涡流传感器在盾构滚刀磨损监测系统中的应用研究[J].隧道建设,2016,36(6):766.LI Dongli,SUN Zhihong,REN Dezhi,et al.Study of application of eddy-current sensor to disc cutter wear monitoring system of shield machines[J].Tunnel Construction,2016,36(6):766.
[2] 竺维彬,鞠世健.复合地层中的盾构施工技术[M].北京:中国科学技术出版社,2006.ZHU Weibin,JU Shijian.Shield tunneling technology in mixed ground conditions[M].Beijing:China Science and Technology Press,2006.
[3] 李俊伟,李丽琴,吕培印.复合地层条件下盾构选型的风险分析[J].地下空间与工程学报,2007(增刊1):1241.LI Junwei,LI Liqin,LYU Peiyin.Risk analysis of shield type selection at composite strata[J].Chinese Journal of Underground Space and Engineering,2007(S1):1241.
[4] 吴起星,安关峰,周小文,等.软硬复合地层中盾构掘进刀盘受力分析与计算[J].土木工程学报,2015,48(增刊2):321.WU Qixing,AN Guanfeng,ZHOU Xiaowen,et al.Cutterhead mechanical analysis of shield tunneling in soft and hard complex strata[J].China Civil Engineering Journal,2015,48(S2):321.
[5] 周骏,戴佳临,张天举.复合式盾构机刀盘刀具的设计及选型分析[J].公路,2014(6):306.ZHOU Jun,DAI Jialin,ZHANG Tianju.Design and type selection analysis of cutterhead for composite shield machine[J].Highway,2014(6):306.
[6] 陈健.大直径盾构刀盘刀具选型及常压换刀技术研究[J].隧道建设(中英文),2018,38(1):110.CHEN Jian.Study of cutterhead and cutting tool selection and cutting tool replacement of large-diameter shield under atmospheric condition[J].Tunnel Construction,2018,38(1):110.
[7] 张建水,冀亚仙,张艳峰,等.基于ANSYS的掘进机刀盘模态分析与研究[J].机械设计,2016(9):101.ZHANG Jianshui,JI Yaxian,ZHANG Yanfeng,et al.Modal analysis of boring machine cutterhead based on ANSYS[J].Journal of Machine Design,2016(9):101.
[8] 夏毅敏,吴才章,兰浩,等.典型TBM刀盘力学性能分析与对比[J].哈尔滨工程大学学报,2016,37(8):1136.XIA Yimin,WU Caizhang,LAN Hao,et al.Mechanical performance analysis and comparison of typical TBM cutterhead[J].Journal of Harbin Engineering University,2016,37(8):1136.
[9] 曾文宇,管会生,宋颖鹏,等.煤矿斜井双模式盾构刀盘的受力特性研究[J].工程设计学报,2017,24(1):77.ZENG Wenyu,GUAN Huisheng,SONG Yingpeng,et al.Study of stress characteristics of cutter head of dual-mode shield machine used for inclinded shaft of colliery[J].Chinese Journal of Engineering Design,2017,24(1):77.
[10] 韩亚丽,吕传田,张宁川.北京铁路地下直径线盾构选型及功能设计[J].中国工程科学,2010,12(12):29.HAN Yali,LYU Chuantian,ZHANG Ningchuan.Shield selection and function design of Beijing underground diameter line[J].Engineering Sciences,2010,12(12):29.
[11] 王凯,陈馈,孙振川,等.基于复合磨蚀试验台的滚刀磨损试验研究[J].隧道建设(中英文),2018,38(1):142.WANG Kai,CHEN Kui,SUN Zhenchuan,et al.Experimental study of disc cutter wear based on composite abrasion test platform[J].Tunnel Construction,2018,38(1):142.
[12] 王玮,李自贵,赵海峰,等.全断面掘进机综合试验机刀盘有限元分析[J].机械设计与制造,2013(6):137.WANG Wei,LI Zigui,ZHAO Haifeng,et al.Finite element analysis on the comprehensive testing machine of tunnel boring machine cutter head[J].Machinery Design & Manufacture,2013(6):137.
[13] 周阳宗,聂羽飞,李杰,等.某型复合盾构刀盘的有限元静动态特性分析与优化[J].现代隧道技术,2015,52(3):144.ZHOU Yangzong,NIE Yufei,LI Jie,et al.Static and dynamic FEM analyses and optimization of a mix-shield cutterhead[J].Modern Tunnelling Technology,2015,52(3):144.
[14] 王凯,张仕民.压裂车车架动态特性分析[J].科学技术与工程,2017,17(31):346.WANG Kai,ZHANG Shimin.Dynamic characteristics analysis of fracturing truck frame[J].Science Technology and Engineering,2017,17(31):346.
[15] 李东利,孙志洪,任德志,等.电涡流传感器在盾构滚刀磨损监测系统中的应用研究[J].隧道建设,2016,36(6):766.LI Dongli,SUN Zhihong,REN Dezhi,et al.Study of application of eddy-current sensor to disc cutter wear monitoring system of shield machines[J].Tunnel Construction,2016,36(6):766.