盾构刀具切削研究进展及非正常磨损实例分析
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摘要
盾构刀具在切削岩土体过程中的受力形态和磨损情况是决定工程施工顺利与否的关键因素之一。然而,在穿越高磨蚀性的砂卵石及土岩复合地层时,常会面临因刀具过量磨损而导致盾构机无法正常掘进等难题。针对刀具切削岩土体过程的受力与磨损问题,从刀具磨损监测方法、切削机理、切削过程受力的试验和数值模拟等方面系统地总结了近年来的相关研究进展,并通过典型工程案例分析了目前严重困扰盾构掘进的刀具非正常磨损问题。关于刀具磨损监测方法,目前通电式和超声波式监测技术在盾构施工中被广泛应用,并逐步发展形成连续成像的摄影测量和DCRM技术;在刀具切削力学模型方面,重点阐述了滚刀张拉破岩模式和CSM力学模型,以及刮刀的流动切削模型和Mckyes-Ali模型;刀具切削和磨损试验分别从岩土磨蚀单元试验、单个刀具切削试验和刀盘整体切削的模型试验3个方面研究刀具切削磨损效果;数值模拟研究则偏重于研究岩土体在不同的切削条件下应力状态和破碎形态的变化情况;刀具非正常磨损直接缩短刀具的使用寿命,具有突发性和不规律性的特点,是工程实际中最为典型的刀具磨损方式。最后,针对盾构刀具切削与磨损形式,展望了盾构刀具切削磨损在刀具监测方式、外形及布置方式、合金材料和焊接工艺等方面的发展趋势。
The force and wear condition of shield cutters during the cutting of rock and soil is a key factor in determining whether a construction project is successful or not. However, when shield machines cross highly abrasive sand pebble strata and soil-rock composite formations, they often cannot bore properly due to excessive wear on the tool. In order to solve the problem of force and wear from the soil-rock mass cutting process, the research progress of cutter wear monitoring methods, cutting mechanisms, and experiments and numerical simulations of stress in the cutting process are summarized in this paper. Through typical engineering cases, the abnormal wear problems of the tools seriously disturbed by shield tunneling are analyzed. Regarding tool wear monitoring methods, electrical and ultrasonic monitoring technologies are widely used in shield construction, and photogrammetry and DCRM technology for continuous imaging have been gradually developing. With respect to the tool cutting mechanical model, this paper focuses on the tensile-fractured model and the CSM mechanical model of the disc cutter, as well as the flow cutting model and the Mckyes-Ali model of the scraper. Tool cutting and wear experiments are studied in three aspects: geotechnical erosion unit experiments, single tool cutting experiments, and tool overall cutting model experiments. Numerical simulation studies focus on the study of the stress state and the fracture morphology of rock and soil under different cutting conditions. The abnormal wear of the tool directly shortens the service life of the tool, and is also abrupt and irregular. It is the most typical tool wear model in engineering practice. Finally, looking at the cutting and wear forms of shield cutters, this paper provides an outline of the developing trend of cutters in tool monitoring mode, shape and arrangement, alloy materials, and the welding process.
The force and wear condition of shield cutters during the cutting of rock and soil is a key factor in determining whether a construction project is successful or not. However, when shield machines cross highly abrasive sand pebble strata and soil-rock composite formations, they often cannot bore properly due to excessive wear on the tool. In order to solve the problem of force and wear from the soil-rock mass cutting process, the research progress of cutter wear monitoring methods, cutting mechanisms, and experiments and numerical simulations of stress in the cutting process are summarized in this paper. Through typical engineering cases, the abnormal wear problems of the tools seriously disturbed by shield tunneling are analyzed. Regarding tool wear monitoring methods, electrical and ultrasonic monitoring technologies are widely used in shield construction, and photogrammetry and DCRM technology for continuous imaging have been gradually developing. With respect to the tool cutting mechanical model, this paper focuses on the tensile-fractured model and the CSM mechanical model of the disc cutter, as well as the flow cutting model and the Mckyes-Ali model of the scraper. Tool cutting and wear experiments are studied in three aspects: geotechnical erosion unit experiments, single tool cutting experiments, and tool overall cutting model experiments. Numerical simulation studies focus on the study of the stress state and the fracture morphology of rock and soil under different cutting conditions. The abnormal wear of the tool directly shortens the service life of the tool, and is also abrupt and irregular. It is the most typical tool wear model in engineering practice. Finally, looking at the cutting and wear forms of shield cutters, this paper provides an outline of the developing trend of cutters in tool monitoring mode, shape and arrangement, alloy materials, and the welding process.
引文
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