盾构刀具磨损机理及预测分析
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摘要
为准确判断和预测盾构刀具服役寿命周期,指导盾构掘进施工,采用理论分析推导和实测工程数据分析的方法,对盾构隧道掘进过程中的刀具磨损机理和磨损预测模型进行分析研究。基于金属摩擦学理论,分析得到盾构刀具磨损主要由磨粒磨损、黏着磨损和疲劳磨损3种机制共同组成,其中磨粒磨损和黏着磨损是盾构刀具磨损的主要原因。针对盾构掘进刀具磨损定量计算,考虑磨粒磨损、黏着磨损和疲劳磨损共同作用,结合Rabinowicz磨粒磨损、Archard黏着磨损和疲劳磨损计算公式,引入科罗拉多矿业大学滚刀破岩力学模型和中南大学切刀破岩力学模型,推导得到盾构滚刀和切刀磨损预测通用计算模型;基于大连某盾构区间的复杂地层刀具磨损实测数据,借助于MATLAB软件编程,对实测数据进行分析,并与预测模型计算值对比。结果表明:模型预测值与实测磨损数据的误差小于15%,表明了预测模型具有较好的准确性;采用该模型对不同地层条件下刀具磨损量预测可行,研究结果对盾构掘进中的刀具磨损预测和开仓换刀时机选择具有较好的指导意义和工程实际意义。
In order to accurately determine and predict the service life cycle of shield cutter with the purpose of guiding the shield tunneling,the wear mechanism and wear prediction model of shield cutters were analyzed by dint of theoretical analysis and measured engineering data validation.Based on the metal tribology theory,shield cutter wear was composed of abrasive wear,adhesive wear and fatigue wear.The abrasive wear and adhesive wear were the main reasons of shield cutter-wear.In allusion to the quantitative calculation of cutting-tool wear of shield excavation,combined with Rabinowicz abrasive wear equation,Archard adhesive wear equation and fatigue wear equation,the hob and cutter prediction models were established by introducing the CSM(Colorado School of Mines)'s rock-breaking mechanics model of hob and CSU(Central South University)'s rock-breaking mechanics model of cutting-tool.The measureddata of complex stratum of the shield tunneling in Dalian Metro(DM)was analyzed by MATLAB software and compared with calculated values of prediction model.The results show that the error between predicted value and measured value is less than 15% with implication that prediction model is accurate.The proposed model is feasible to predict the wear of the cutter under different formation conditions.The results with engineering significance can provide references for the cutter wear prediction and exchanges of cutting tools in opening chamber during shield tunneling in future.
In order to accurately determine and predict the service life cycle of shield cutter with the purpose of guiding the shield tunneling,the wear mechanism and wear prediction model of shield cutters were analyzed by dint of theoretical analysis and measured engineering data validation.Based on the metal tribology theory,shield cutter wear was composed of abrasive wear,adhesive wear and fatigue wear.The abrasive wear and adhesive wear were the main reasons of shield cutter-wear.In allusion to the quantitative calculation of cutting-tool wear of shield excavation,combined with Rabinowicz abrasive wear equation,Archard adhesive wear equation and fatigue wear equation,the hob and cutter prediction models were established by introducing the CSM(Colorado School of Mines)'s rock-breaking mechanics model of hob and CSU(Central South University)'s rock-breaking mechanics model of cutting-tool.The measureddata of complex stratum of the shield tunneling in Dalian Metro(DM)was analyzed by MATLAB software and compared with calculated values of prediction model.The results show that the error between predicted value and measured value is less than 15% with implication that prediction model is accurate.The proposed model is feasible to predict the wear of the cutter under different formation conditions.The results with engineering significance can provide references for the cutter wear prediction and exchanges of cutting tools in opening chamber during shield tunneling in future.
引文
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[15]王旭,赵羽,张宝刚,等.TBM滚刀刀圈磨损机理研究[J].现代隧道技术,2010,47(5):15-19.WANG Xu,ZHAO Yu,ZHANG Bao-gang,et al.The Research on TBM Disc Cutter Wear Mechanism[J].Modern Tunnelling Technology,2010,47(5):15-19.
[16]温诗铸,黄平.摩擦学原理[M].北京:清华大学出版社,2002.WEN Shi-zhu,HUANG Ping.Principles of Tribology[M].Beijing:Tsinghua University Press,2012.
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[18]桂长林.Archard的磨损设计计算模型及其应用方法[J].润滑与密封,1990(1):12-21.GUI Chang-lin.The Archard Design Calculation Model and Its Application Methods[J].Lubrication Engineering,1990(1):12-21.
[19]LIU Y,MAVROIDIS C,BAR-COHEN Y,et al.Optimal Design of the Coring Bit Cutting Edge in Percussive/Vibratory Drilling[C]//American Society of Mechanical Engineers.Proceedings of the ASME 2005International Design Engineering Technical Conferences and Computers and Information in Engineering Conference.Washington DC:ASME,2005:1-10.
[20]暨智勇.盾构掘进机切刀切削软岩和土壤受力模型研究及实验验证[D].长沙:中南大学,2009.JI Zhi-yong.Study and Experimental Research on Cutter Cutting Soft Rocks and Soil Stress Model of Shield Cutters[D].Changsha:Central South University,2009.
[2]张厚美.盾构隧道盘形滚刀损坏的原因分析与对策[J].现代隧道技术,2010,47(6):40-45,50.ZHANG Hou-mei.Analysis of Damages of TBM Disc Cutters and Countermeasures[J].Modern Tunnelling Technology,2010,47(6):40-45,50.
[3]ROSTAMI J.Development of a Force Estimation Model for Rock Fragmentation with Disc Cutters Through Theoretical Modeling and Physical Measurement of Crushed Zone Pressure[M].Golden:Colorado School of Mines,1997.
[4]ZARE S,BRULAND A.Applications of NTNU/SINTEF Drillability Indices in Hard Rock Tunneling[J].Rock Mechanics and Rock Engineering,2013,46(1):179-187.
[5]袁大军,胡显鹏,李兴高,等.砂卵石地层盾构刀具磨损测试分析[J].城市轨道交通研究,2009(5):48-51.YUAN Da-jun,HU Xian-peng,LI Xing-gao,et al.Abrasion Characteristics of Shield Cutters in Sandy Cobble Stratum[J].Urban Mass Transit,2009(5):48-51.
[6]张明富,袁大军,黄清飞,等.砂卵石地层盾构刀具动态磨损分析[J].岩石力学与工程学报,2008,27(2):397-402.ZHANG Ming-fu,YUAN Da-jun,HUANG Qing-fei,et al.Analysis of Dynamic Abrasion of Shield Cutters in Sandy Cobble Stratum[J].Chinese Journal of Rock Mechanics and Engineering,2008,27(2):397-402.
[7]李刚,朱立达,杨建宇,等.基于CSM模型的硬岩TBM滚刀磨损预测方法[J].中国机械工程,2014,25(1):32-35.LI Gang,ZHU Li-da,YANG Jian-yu,et al.A Method to Predict Disc Cutter Extent for Hard Rock TBMs Based on CSM Model[J].China Mechanical Engineering,2014,25(1):32-35.
[8]王立辉.全断面岩石掘进机刀具磨损状态的分析与识别[D].天津:天津大学,2012.WANG Li-hui.Analysis and Recognition of the Wear State of Full-face Rock Tunnel Boring Machine Disc Cutter[D].Tianjin:Tianjin University,2012.
[9]张照煌,纪昌明.全断面岩石掘进机盘形滚刀刃破岩点弧长的解析解及应用研究[J].应用基础与工程科学学报,2009,17(2):265-273.ZHANG Zhao-huang,JI Chang-ming.Analytic Solution and Its Usage of Arc Length of Rock Breakage Point of Disc Edge on Full Face Rock Tunnel Boring Machine[J].Journal of Basic Science and Engineering,2009,17(2):265-273.
[10]赵海鸣,舒标,夏毅敏,等.基于磨料磨损的TBM滚刀磨损预测研究[J].铁道科学与工程学报,2014,11(4):152-158.ZHAO Hai-ming,SHU Biao,XIA Yi-min,et al.Study of Wear Prediction for TBM Cutter Based on Abrasive Wear Model[J].Journal of Railway Science and Engineering,2014,11(4):152-158.
[11]吴俊,袁大军.大连极硬岩地层复合盾构刀具磨损的分析与预测[J].土木工程学报,2015,48(增1):250-255.WU Jun,YUAN Da-jun.Analysis and Prediction on Composite Shield Cutters Wear in Extremely Hard Rock in Dalian Metro[J].China Civil Engineering Journal 2015,48(S1):250-255.
[12]杨俊哲,邱承有.盾构刀具磨损速率预测研究[J].施工技术,2016,45(22):25-30.YANG Jun-zhe.QIU Cheng-you.Prediction of Cutting Tool Wear Rate[J].Construction Technology,2016,45(22):25-30.
[13]赵青,段景川,杨涛,等.风化花岗岩地层的盾构滚刀磨损预测研究[J].路基工程,2016(2):94-98.ZHAO Qing,DUAN Jing-chuan,YANG Tao.et al.Research on Service Life Prediction After Abrasion of Shield Hob in Weathered Granite Formation[J].Subgrade Engineering,2016(2):94-98.
[14]温诗铸.材料磨损研究的进展与思考[J].摩擦学学报,2008,28(1):1-5.WEN Shi-zhu.Research Progress on Wear of Materials[J].Tribology,2008,28(1):1-5.
[15]王旭,赵羽,张宝刚,等.TBM滚刀刀圈磨损机理研究[J].现代隧道技术,2010,47(5):15-19.WANG Xu,ZHAO Yu,ZHANG Bao-gang,et al.The Research on TBM Disc Cutter Wear Mechanism[J].Modern Tunnelling Technology,2010,47(5):15-19.
[16]温诗铸,黄平.摩擦学原理[M].北京:清华大学出版社,2002.WEN Shi-zhu,HUANG Ping.Principles of Tribology[M].Beijing:Tsinghua University Press,2012.
[17]何奖爱,王玉玮.材料磨损与耐磨材料[M].沈阳:东北大学出版社,2001.HE Jiang-ai,WANG Yu-Wei,Material Wear and Wear Materials[M].Shenyang:Northeastern University Press,2001.
[18]桂长林.Archard的磨损设计计算模型及其应用方法[J].润滑与密封,1990(1):12-21.GUI Chang-lin.The Archard Design Calculation Model and Its Application Methods[J].Lubrication Engineering,1990(1):12-21.
[19]LIU Y,MAVROIDIS C,BAR-COHEN Y,et al.Optimal Design of the Coring Bit Cutting Edge in Percussive/Vibratory Drilling[C]//American Society of Mechanical Engineers.Proceedings of the ASME 2005International Design Engineering Technical Conferences and Computers and Information in Engineering Conference.Washington DC:ASME,2005:1-10.
[20]暨智勇.盾构掘进机切刀切削软岩和土壤受力模型研究及实验验证[D].长沙:中南大学,2009.JI Zhi-yong.Study and Experimental Research on Cutter Cutting Soft Rocks and Soil Stress Model of Shield Cutters[D].Changsha:Central South University,2009.