TBM滚刀轴承力学分析与结构优化
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摘要
在隧道和地下工程施工中,全断面岩石隧道掘进机(TBM)具有自动化程度高、安全高效和在超长隧道中连续作业的特点,代表了当代隧道掘进技术的发展方向。在TBM施工中,主要的破岩工具是盘形滚刀。通过大量工程施工实践的证明,刀具损坏严重是影响掘进效率的最重要因素。而在刀具损坏中,滚刀轴承的损坏又是其最常见的损坏形式。
本文首先对盘形滚刀的结构及破岩机理进行简单的介绍,然后利用科罗拉多矿业学院滚刀受力的力学公式对滚刀轴承进行基本的性能分析。在此基础上,我对滚刀轴承进行一个由内到外的结构优化设计。
首先利用数据优化软件对滚刀轴承内部结构主参数进行优化。选取轴承的基本额定动载荷作为优化目标,利用已有的约束条件对其主参数进行优化；然后在加载的情况下对滚刀轴承滚子两端不同的圆弧度和凸度量进行分析,得到不同载荷下滚子最优的圆弧度和凸度量,为滚刀轴承的设计提供了一定依据；最后利用Ansys Workbench软件,分析滚刀轴承内外圈安装过盈量对其初始游隙的影响,并在此基础上得到了工作游隙对滚刀轴承摩擦力矩与寿命的影响,为滚刀轴承的在设计游隙和装配时提供一定参考和帮助。
In the construction of tunnels and underground works, TBM has a high degree of automation, security, efficient and continuous operation in the long tunnel, and represents the direction of development of contemporary tunneling.In the construction of TBM,a disc cutter is the main rock-breaking tool.The serious damage of the tool is the most important factors of affecting the tunneling effciency.In all forms of tool damage,the damage of cutter bearing is the most common form of damage.
Firstly,there is a brief introduction of the structure of the disc cutter and the mechanism of the rock-breaking,and then I analyze the basic mechanical properties of the cutter in the help of the predicted mechanical formula of the Colorado School of Mines. On the basis,I have a design of strcutural optimization of the cutter bearing from the inside to the outside.
Firstly,I do a optimization of the main parameters of the cutter bearing's internal structure using the optimization software.It selects the basic dynamic load rating as the optimization and use the existing constraints.Secondly,I do a design of optimization about the arc degrees and convex metric of the roller in the case of the load and get the optimal arc degrees and optimal convex metric providing some basis for bearing design.Finally,I analyze the affect of the amount of interference to the initial clearance and the influence of the work clearance to the friction torque and the life of the cutter bearing,providing some basis and help for the assembly of the bearing.
本文首先对盘形滚刀的结构及破岩机理进行简单的介绍,然后利用科罗拉多矿业学院滚刀受力的力学公式对滚刀轴承进行基本的性能分析。在此基础上,我对滚刀轴承进行一个由内到外的结构优化设计。
首先利用数据优化软件对滚刀轴承内部结构主参数进行优化。选取轴承的基本额定动载荷作为优化目标,利用已有的约束条件对其主参数进行优化；然后在加载的情况下对滚刀轴承滚子两端不同的圆弧度和凸度量进行分析,得到不同载荷下滚子最优的圆弧度和凸度量,为滚刀轴承的设计提供了一定依据；最后利用Ansys Workbench软件,分析滚刀轴承内外圈安装过盈量对其初始游隙的影响,并在此基础上得到了工作游隙对滚刀轴承摩擦力矩与寿命的影响,为滚刀轴承的在设计游隙和装配时提供一定参考和帮助。
In the construction of tunnels and underground works, TBM has a high degree of automation, security, efficient and continuous operation in the long tunnel, and represents the direction of development of contemporary tunneling.In the construction of TBM,a disc cutter is the main rock-breaking tool.The serious damage of the tool is the most important factors of affecting the tunneling effciency.In all forms of tool damage,the damage of cutter bearing is the most common form of damage.
Firstly,there is a brief introduction of the structure of the disc cutter and the mechanism of the rock-breaking,and then I analyze the basic mechanical properties of the cutter in the help of the predicted mechanical formula of the Colorado School of Mines. On the basis,I have a design of strcutural optimization of the cutter bearing from the inside to the outside.
Firstly,I do a optimization of the main parameters of the cutter bearing's internal structure using the optimization software.It selects the basic dynamic load rating as the optimization and use the existing constraints.Secondly,I do a design of optimization about the arc degrees and convex metric of the roller in the case of the load and get the optimal arc degrees and optimal convex metric providing some basis for bearing design.Finally,I analyze the affect of the amount of interference to the initial clearance and the influence of the work clearance to the friction torque and the life of the cutter bearing,providing some basis and help for the assembly of the bearing.
引文
[1]刘天行.TBM在铁路隧道施工中的应用研究[J].中国新技术新产品,2009(11)：8.
[2]Remo Grandori. TBM Design Developments and Innovation for Large Diameter Tunnels under High Cover and Complex Geologies[J]. Tunnel Construction,2012,32(1):1-4.
[3]Reilly John,Arrigoni Gianni, Xu Shulin, et al.TBM and Application China(1)[J]. Modern Tunnelling Technology,2002,39(1).
[4]Reilly John, Arrigoni Gianni, Xu Shulin,et al.TBM and Application China(2)[J]. Modern Tunnelling Technology,2002,39(2).
[5]Reilly John, Arrigoni Gianni,Xu Shulin,et al.TBM and Application China(3)[J]. Modern Tunnelling Technology,2002,39(3).
[6]Reilly John, Arrigoni Gianni,Xu Shulin,et al.TBM and Application China(4)[J]. Modern Tunnelling Technology,2002,39(4).
[7]陈馈,洪开容,吴学松,等.盾构施工技术[M].北京：人民交通出版社,2009.
[8]竺维彬,王晖,鞠世健.复合地层中盾构滚刀磨损原因分析与对策[J].现代隧道技术,2006(04)：72-75.
[9]刘晓毅.复合地层中盾构机滚刀磨损原因分析及改进[J].隧道建设,2006,26：77-80.
[10]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,2010,12(06)40-45.
[11]杨晓蔚,刘建德,蒋兴奇.英制圆锥滚子轴承的设计技术规范与要点[J].轴承,1996(04)：5-9.
[12]扬金强.盘型滚刀受力分析及切割岩石数值模拟研究[D].河北：华北电力大学,2007.
[13]张庆贵.硬岩掘进机盘型滚刀载荷谱编制[D].辽宁：东北大学,2008.
[14]张勇智.硬岩隧道掘进机(TBM)刀具的管理[J].现代隧道技术,2007.
[15]刘春.TBM掘进机关键部件——盘型滚刀的研制[J].中国铁道科学,2003,(04)：101-106.
[16]张厚美.盾构盘型滚刀损坏机理的力学分析与应用[J].现代隧道技术,2011,48(1)：61-65.
[17]Rostami J, Ozdemir L. A New Mpdel For Performance Prediction of Hard Rock TBMs[C]. Boston MA:1993,793-809.
[18]余静,液压破岩机理和参数计算[J].金属矿山,1981(07)：6-10.
[19]张照煌.全断面岩石掘进机盘形滚刀破岩机理的探讨[J].矿山机械,1995(10)：27-29.
[20]Rostami J, Ozdemir L, Nilson B. Comparison Between CSM and NTH Hard Rock TBM Performance Prediction Models[C].LAS VEGAS NV:1996,1-11.
[21]Sanio H P. Prediction of the performance of disc cutters in anisotropic rock[J]. International Journal of Rock Mechanics and Mining Science & Geomechanics Abstracts,1985,22 (3):153-161.
[22]宋克志,袁大军,王梦恕.盘型滚刀与岩石相互作用研究综述[J].铁道工程学报,2005(06)：66-69.
[23]孙鸿范,陈健元,陈刚.掘进机盘型滚刀破岩力及计算载荷的研究[J].工程机械,1980(08)：1-7.
[24]吴起星.复合地层中盾构机滚刀破岩力学分析[D].广东：暨南大学,2011.
[25]张魁.盾构机盘型滚刀作用下岩石破碎特征及滚刀振动特性研究[D].湖南：中南大学,2010.
[26]屠昌锋.盾构机盘型滚刀垂直力和侧向力预测模型研究[D].湖南：中南大学,2009.
[27]Ozdemir. L., Wang FunDen. Mechanical Tunnel Boring Prediction and Machine Design(Final Report)[C]. Colorado School of Mines,1979,24(5):33-35.
[28]Bernhard Maidl,Martin Herrenknecht, Lotharn heuser[J].Mechanised shield Tunnelling,1996,34(5):37-39.
[29]赵章荣,隋晓梅,黄轶,等.基于改进自适应遗传算法的圆锥滚子轴承优化设计[J].机床与液压,2008,36(08)：21-23.
[30]张晓冬,何玉林.圆锥滚子轴承多目标优化设计[J].机械设计与研究,1997(01)：41-43.
[31]王大力,徐浩.圆锥滚子轴承最优主参数的快速确定方法[J].轴承,1999(03)：1-4.
[32]李元科,余俊.圆锥滚子轴承优化设计及计算机辅助设计——TRBD系统[J].轴承,1986(04)：1-15.
[33]徐淑萍,康十臣.圆锥滚子轴承滚动母线凸度设计与测量[J].沈阳理工大学学报,2008,27(05)：17-19.
[34]曲国杰,徐林红,邢勤.圆锥滚子轴承滚动体的凸度分析[J].哈尔滨轴承,2008,29(03)：14.
[35]吴飞科.圆锥滚子轴承接触应力分析及凸度设计[D].河南：河南科技大学,2007.
[36]马文博.基于接触分析的凸度滚子轴承力学特性研究与结构优化[D].江苏：南京航空航天大学,2009.
[37]Chen Junhua, Wu Yi jie. Analysis of 3D Curve Expansion of Conical Cam with Osci Hating Tapered Roller Follower[J]. Journal of Zhejiang University SCIENCE A,2007.
[38]徐淑萍,马金明.圆柱滚子轴承游隙与寿命关系[J].沈阳理工大学学报,2011,30(04)：43-47.
[39]刘晓初.有效过盈量对轴承径向工作游隙的影响[J].轴承,1996,(11)：11-12.
[40]黄其圣,吕永香.配合对向心球轴承游隙和承载能力的影响[J].合肥工业大学学报,1993,16：95-101.
[41]王伟,张亚琴.滚动轴承径向游隙的选择及计算实例[J].煤矿机械,2012,33(02)：26-27.
[42]朱爱华,朱成九,张卫华.滚动轴承摩擦力矩的计算分析[J].轴承,2008, (07)：13.
[43]张茂亮,彭晓红.降低圆锥滚子轴承摩擦力矩的方法[J].轴承,2006, (09)：4-5.
[44]王金伟,赵丹,李倩.预紧力对滚动轴承游隙的影响[J].纺织器材,2007,34(06)：500-502.
[45]杨咸启,赵广炎.外圈带紧固环的双列圆锥滚子轴承寿命计算[J].轴承,2000, (06)：4-6.
[46]郭婧.滚动轴承疲劳寿命综述[J].甘肃科技,2006,22(04)：133-134.
[47]陈玉莲,肖树红,陈署泉,等.高速角接触球轴承接触疲劳寿命的有限元分析[J].机械设计与制造,2009, (09)：9-12.
[48]曾春华,邹十践.疲劳分析方法及应用[M].北京：国防工业出版社,1991.
[49]郭岱,金婷,余波.微面后驱动桥半轴滚动轴承疲劳寿命分析[J].车辆与动力技术,2010,(04)：46-48.
[2]Remo Grandori. TBM Design Developments and Innovation for Large Diameter Tunnels under High Cover and Complex Geologies[J]. Tunnel Construction,2012,32(1):1-4.
[3]Reilly John,Arrigoni Gianni, Xu Shulin, et al.TBM and Application China(1)[J]. Modern Tunnelling Technology,2002,39(1).
[4]Reilly John, Arrigoni Gianni, Xu Shulin,et al.TBM and Application China(2)[J]. Modern Tunnelling Technology,2002,39(2).
[5]Reilly John, Arrigoni Gianni,Xu Shulin,et al.TBM and Application China(3)[J]. Modern Tunnelling Technology,2002,39(3).
[6]Reilly John, Arrigoni Gianni,Xu Shulin,et al.TBM and Application China(4)[J]. Modern Tunnelling Technology,2002,39(4).
[7]陈馈,洪开容,吴学松,等.盾构施工技术[M].北京：人民交通出版社,2009.
[8]竺维彬,王晖,鞠世健.复合地层中盾构滚刀磨损原因分析与对策[J].现代隧道技术,2006(04)：72-75.
[9]刘晓毅.复合地层中盾构机滚刀磨损原因分析及改进[J].隧道建设,2006,26：77-80.
[10]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,2010,12(06)40-45.
[11]杨晓蔚,刘建德,蒋兴奇.英制圆锥滚子轴承的设计技术规范与要点[J].轴承,1996(04)：5-9.
[12]扬金强.盘型滚刀受力分析及切割岩石数值模拟研究[D].河北：华北电力大学,2007.
[13]张庆贵.硬岩掘进机盘型滚刀载荷谱编制[D].辽宁：东北大学,2008.
[14]张勇智.硬岩隧道掘进机(TBM)刀具的管理[J].现代隧道技术,2007.
[15]刘春.TBM掘进机关键部件——盘型滚刀的研制[J].中国铁道科学,2003,(04)：101-106.
[16]张厚美.盾构盘型滚刀损坏机理的力学分析与应用[J].现代隧道技术,2011,48(1)：61-65.
[17]Rostami J, Ozdemir L. A New Mpdel For Performance Prediction of Hard Rock TBMs[C]. Boston MA:1993,793-809.
[18]余静,液压破岩机理和参数计算[J].金属矿山,1981(07)：6-10.
[19]张照煌.全断面岩石掘进机盘形滚刀破岩机理的探讨[J].矿山机械,1995(10)：27-29.
[20]Rostami J, Ozdemir L, Nilson B. Comparison Between CSM and NTH Hard Rock TBM Performance Prediction Models[C].LAS VEGAS NV:1996,1-11.
[21]Sanio H P. Prediction of the performance of disc cutters in anisotropic rock[J]. International Journal of Rock Mechanics and Mining Science & Geomechanics Abstracts,1985,22 (3):153-161.
[22]宋克志,袁大军,王梦恕.盘型滚刀与岩石相互作用研究综述[J].铁道工程学报,2005(06)：66-69.
[23]孙鸿范,陈健元,陈刚.掘进机盘型滚刀破岩力及计算载荷的研究[J].工程机械,1980(08)：1-7.
[24]吴起星.复合地层中盾构机滚刀破岩力学分析[D].广东：暨南大学,2011.
[25]张魁.盾构机盘型滚刀作用下岩石破碎特征及滚刀振动特性研究[D].湖南：中南大学,2010.
[26]屠昌锋.盾构机盘型滚刀垂直力和侧向力预测模型研究[D].湖南：中南大学,2009.
[27]Ozdemir. L., Wang FunDen. Mechanical Tunnel Boring Prediction and Machine Design(Final Report)[C]. Colorado School of Mines,1979,24(5):33-35.
[28]Bernhard Maidl,Martin Herrenknecht, Lotharn heuser[J].Mechanised shield Tunnelling,1996,34(5):37-39.
[29]赵章荣,隋晓梅,黄轶,等.基于改进自适应遗传算法的圆锥滚子轴承优化设计[J].机床与液压,2008,36(08)：21-23.
[30]张晓冬,何玉林.圆锥滚子轴承多目标优化设计[J].机械设计与研究,1997(01)：41-43.
[31]王大力,徐浩.圆锥滚子轴承最优主参数的快速确定方法[J].轴承,1999(03)：1-4.
[32]李元科,余俊.圆锥滚子轴承优化设计及计算机辅助设计——TRBD系统[J].轴承,1986(04)：1-15.
[33]徐淑萍,康十臣.圆锥滚子轴承滚动母线凸度设计与测量[J].沈阳理工大学学报,2008,27(05)：17-19.
[34]曲国杰,徐林红,邢勤.圆锥滚子轴承滚动体的凸度分析[J].哈尔滨轴承,2008,29(03)：14.
[35]吴飞科.圆锥滚子轴承接触应力分析及凸度设计[D].河南：河南科技大学,2007.
[36]马文博.基于接触分析的凸度滚子轴承力学特性研究与结构优化[D].江苏：南京航空航天大学,2009.
[37]Chen Junhua, Wu Yi jie. Analysis of 3D Curve Expansion of Conical Cam with Osci Hating Tapered Roller Follower[J]. Journal of Zhejiang University SCIENCE A,2007.
[38]徐淑萍,马金明.圆柱滚子轴承游隙与寿命关系[J].沈阳理工大学学报,2011,30(04)：43-47.
[39]刘晓初.有效过盈量对轴承径向工作游隙的影响[J].轴承,1996,(11)：11-12.
[40]黄其圣,吕永香.配合对向心球轴承游隙和承载能力的影响[J].合肥工业大学学报,1993,16：95-101.
[41]王伟,张亚琴.滚动轴承径向游隙的选择及计算实例[J].煤矿机械,2012,33(02)：26-27.
[42]朱爱华,朱成九,张卫华.滚动轴承摩擦力矩的计算分析[J].轴承,2008, (07)：13.
[43]张茂亮,彭晓红.降低圆锥滚子轴承摩擦力矩的方法[J].轴承,2006, (09)：4-5.
[44]王金伟,赵丹,李倩.预紧力对滚动轴承游隙的影响[J].纺织器材,2007,34(06)：500-502.
[45]杨咸启,赵广炎.外圈带紧固环的双列圆锥滚子轴承寿命计算[J].轴承,2000, (06)：4-6.
[46]郭婧.滚动轴承疲劳寿命综述[J].甘肃科技,2006,22(04)：133-134.
[47]陈玉莲,肖树红,陈署泉,等.高速角接触球轴承接触疲劳寿命的有限元分析[J].机械设计与制造,2009, (09)：9-12.
[48]曾春华,邹十践.疲劳分析方法及应用[M].北京：国防工业出版社,1991.
[49]郭岱,金婷,余波.微面后驱动桥半轴滚动轴承疲劳寿命分析[J].车辆与动力技术,2010,(04)：46-48.