Theoretical prediction of wear of disc cutters in tunnel boring machine and its application
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摘要
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.
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.
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.
引文
ASTM D7625-10. Standard test method for laboratory determination of abrasiveness of rock using the CERCHAR method. West Conshohocken, PA, USA:ASTM International; 2010.
Bruland A. Hard rock tunnel boring. PhD Thesis. Norwegian University of Science and Technology; 2000.
Farrokh E, Rostami J, Laughton C. Hard rock TBMs'advance rate:discussion and evaluation. In:Proceedings of North American tunneling(NAT). NAT; 2012.p. 179-85.
Frenzel C. Disc cutter wear phenomenology and their implications on disc cutter consumption for TBM. Proceedings of the 45th American rock mechanics association(ARM A)symposium. ARM A; 2011. p. 48-55.
Gehring K. Prognosis of advance rates and wears for underground mechanized excavations. Felsbau 1995; 13(6):439-48[in German].
Hassanpour J, Rostami J, Tarigh Azali S, Zhao J. Introduction of an empirical TBM cutter wear prediction model for pyrocdastic and mafic igneous rocks; a case history of Karaj water conveyance tunnel, Iran. Tunnelling and Underground Space Technology 2014;43(7):222-31.
Hassanpour J, Rostami J, Zhao J, Tarigh Azali S. TBM performance and disc cutter wear prediction based on ten years'experience of TBM tunneling in Iran.Geomechanics and Tunnelling 2015;8(3):239-47.
Liu QS, Liu JP, Pan YC, Zhang XP, Peng XX, Gong QM, Du LJ. A wear rule and cutter life prediction model of a 20-in. TBM cutter for granite:a case study of a water conveyance tunnel in China. Rock Mechanics and Rock Engineering 2017;50(5):1303-20.
Maidl B, Schmidz L, Ritz W, Herrenknecht M. Hard rock tunnel boring machines.Ernst&Sohn; 2008.
Nelson PP, Al-Jalil YA, Laughton C. Tunnel boring machine project data bases and construction simulation. Geotechnical Engineering Report GR94-4. The University of Texas at Austin; 1994.
Rostami J. Development of a force estimation model for rock fragmentation with disc cutters through theoretical modeling and physical measurement of crushed zone pressure. PhD Thesis. Colorado School of Mines; 1997.
Wang LH, Kang YL, Zhao XJ, Zhang Q. Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis. Tunnelling and Underground Space Technology 2015;50:324-33.
Wang LH, Li HP, Zhao XJ, Zhang Q. Development of a prediction model for the wear evolution of disc cutters on rock TBM cutterhead. Tunnelling and Underground Space Technology 2017;67:147-57.
Zhang Z, Ji C. Analytic solution and its usage of arc length of rock breakage point of disc edge on full face rock tunnel boring machine. Journal of Basic Science and Engineering 2009; 17(2):265-73[in Chinese].
Zhang ZH, Meng L, Sun F. Wear analysis of disc cutters of full face rock tunnel boring machine. Chinese Journal of Mechanical Engineering 2014;27(6):1294-300[in Chinese].
Zhao W, Liu M, Du Y, Zhang Z. Abnormal cutter wear recognition of full face tunnel boring machine(TBM). China Mechanical Engineering 2007; 18(2):150-3[in Chinese].
Bruland A. Hard rock tunnel boring. PhD Thesis. Norwegian University of Science and Technology; 2000.
Farrokh E, Rostami J, Laughton C. Hard rock TBMs'advance rate:discussion and evaluation. In:Proceedings of North American tunneling(NAT). NAT; 2012.p. 179-85.
Frenzel C. Disc cutter wear phenomenology and their implications on disc cutter consumption for TBM. Proceedings of the 45th American rock mechanics association(ARM A)symposium. ARM A; 2011. p. 48-55.
Gehring K. Prognosis of advance rates and wears for underground mechanized excavations. Felsbau 1995; 13(6):439-48[in German].
Hassanpour J, Rostami J, Tarigh Azali S, Zhao J. Introduction of an empirical TBM cutter wear prediction model for pyrocdastic and mafic igneous rocks; a case history of Karaj water conveyance tunnel, Iran. Tunnelling and Underground Space Technology 2014;43(7):222-31.
Hassanpour J, Rostami J, Zhao J, Tarigh Azali S. TBM performance and disc cutter wear prediction based on ten years'experience of TBM tunneling in Iran.Geomechanics and Tunnelling 2015;8(3):239-47.
Liu QS, Liu JP, Pan YC, Zhang XP, Peng XX, Gong QM, Du LJ. A wear rule and cutter life prediction model of a 20-in. TBM cutter for granite:a case study of a water conveyance tunnel in China. Rock Mechanics and Rock Engineering 2017;50(5):1303-20.
Maidl B, Schmidz L, Ritz W, Herrenknecht M. Hard rock tunnel boring machines.Ernst&Sohn; 2008.
Nelson PP, Al-Jalil YA, Laughton C. Tunnel boring machine project data bases and construction simulation. Geotechnical Engineering Report GR94-4. The University of Texas at Austin; 1994.
Rostami J. Development of a force estimation model for rock fragmentation with disc cutters through theoretical modeling and physical measurement of crushed zone pressure. PhD Thesis. Colorado School of Mines; 1997.
Wang LH, Kang YL, Zhao XJ, Zhang Q. Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis. Tunnelling and Underground Space Technology 2015;50:324-33.
Wang LH, Li HP, Zhao XJ, Zhang Q. Development of a prediction model for the wear evolution of disc cutters on rock TBM cutterhead. Tunnelling and Underground Space Technology 2017;67:147-57.
Zhang Z, Ji C. Analytic solution and its usage of arc length of rock breakage point of disc edge on full face rock tunnel boring machine. Journal of Basic Science and Engineering 2009; 17(2):265-73[in Chinese].
Zhang ZH, Meng L, Sun F. Wear analysis of disc cutters of full face rock tunnel boring machine. Chinese Journal of Mechanical Engineering 2014;27(6):1294-300[in Chinese].
Zhao W, Liu M, Du Y, Zhang Z. Abnormal cutter wear recognition of full face tunnel boring machine(TBM). China Mechanical Engineering 2007; 18(2):150-3[in Chinese].