盾构机模拟试验台结构设计及刀片磨损的研究
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摘要
盾构法是在土层或岩层中暗挖隧道的一种方法,具有施工速度快、振动小、噪声低、对周围环境影响较小等优点。盾构施工法作为现代隧道施工最先进的工法代表,在国内外运用非常广泛。盾构机是盾构施工法的主要设备,而盾构机的刀盘与刀具作为盾构机的开挖土体部件,在盾构施工中起着非常关键的作用。在地层中施工,盾构刀具磨耗严重,容易磨损脱落。一旦出现这种情况,将导致刀盘扭矩上升,施工困难。研究如何减少刀具磨损,到盾构施工具有重要的意义。
本文研制了一种盾构机模拟试验系统,包括试验台鞍座、土箱、切削机构、输送机构、液压系统等。该试验系统可以模拟对各种地质条件岩土的掘进,为施工工艺参数和技术决策提供科学依据。
在核心参数计算基础上,设计了试验台的刀盘、刀盘驱动系统、推进系统、输送系统、土箱等部件。对于液压系统进行了设计和计算。对整个系统设计的液压元件、减速箱以及各种传感器进行了元件选型。
论文以土力学、岩石破碎学为基础,从土体性能研究入手,对不同盾构刀具切削机理进行研究,通过对刀盘扭矩构成因素的全面分析,建立了刀盘扭矩估算的理论模型,导出了各扭矩分量的计算公式,由岩土性能参数分析计算了切削刀具的受力,分别计算出刀盘上每把刀具所承受的力和扭矩。
论文系统分析了刀具的磨损原因和影响因素,并通过算例说明刀具寿命预测的分析方法,运用掘进参数检测滚刀的失效原理,滚刀磨损和失效的判断方法,介绍了刀具失效的常用判断方法,并给出了提高刀具寿命的建议。
运用PRO/E设计软件对盾构机模拟试验台的主要组件进行了结构设计,利用有限元分析软件ANSYS对主轴和切削刀具工作过程中所受的剪切力进行了有限元分析,为刀具的选择、安全系数的选取等提供了重要参考。
Shield method is a way of tunneling in soft or rock,it has many advantages,such as high speed,high precision,small vibration,low noise,has little impact on the surrounding environment,etc.As a representative of the most advanced tunneling techniques of today,tunnel boring method is applied very widely both at home and abroad.Shield tunneling machine is the main equitment of this new method,and the shield cutter and the cutter pan are the main tunneling part of the tunnel boring machine and play a very important role in tunnel boring construction.When tunneling in stratum,the abrasiong of shield cutters is serious,meanwhile the cutter bits are easily chip and scale.If such situations occur,the cutter torque will become higher and the shield will hard to advance.Therefore,it is of great signigicance to research on reducing the abrasion of cutters.
A new developed shield tunneling test system was introduced by this thesis.This test system inclueded test saddle,soil box,cutting head conveyer system,hydraulic system,etc.The test system was used for excavating experiments in different soil and rock,and the results of the experiment will be used to support for better tunneling organization.
Based on parameters obtained by theoretical study,the overall mechanical system was designed.Parts such as cutter head,driven system,trust system,conveyer system and soil box all designed through calculation.The hydraulic system was also designed through detailed calculation.All standard patrts involved in the test system included hydraulic component,gear box and sensors were selected by calculation.
This thesis based on soil and rock mechanics,studied the cutting mechanism of the different shield cutters in accordance with the different soil bodies,based on the knowledge of soil body performance and the simulation test of tunnel boring machine through different soil bodies. A theoreticalmodel was proposed based on the systematic analysis of cutter head torque in shield tunneling. Formulae of calculating torque components in this model were deduced.Forces on cutters when cutting soil or rock were analysed and calculated based on soil and rock mechanics.Furthermore,the force and torque of each cutter was calculated.
The abrasion reasons and influencing factors of all kinds of cutters were analyzed in this thesis.The cutters life were analysed according to calculating.General approaches for estimating the cutter wear,the principle of estimating the cutter wear and case studies are also introduced.Suggestions were given to increase cutters life.
In the use of three-dimensional designed software Pro/ENGINEER design the main parts of the shield tunneling machine simulated bedstand equipment. At last analyse the shearing force of principal axis and cutters by finite element analysis software ANSYS. By analysis the results, important reference for the structure and safety factor choose of cutters was provided.
本文研制了一种盾构机模拟试验系统,包括试验台鞍座、土箱、切削机构、输送机构、液压系统等。该试验系统可以模拟对各种地质条件岩土的掘进,为施工工艺参数和技术决策提供科学依据。
在核心参数计算基础上,设计了试验台的刀盘、刀盘驱动系统、推进系统、输送系统、土箱等部件。对于液压系统进行了设计和计算。对整个系统设计的液压元件、减速箱以及各种传感器进行了元件选型。
论文以土力学、岩石破碎学为基础,从土体性能研究入手,对不同盾构刀具切削机理进行研究,通过对刀盘扭矩构成因素的全面分析,建立了刀盘扭矩估算的理论模型,导出了各扭矩分量的计算公式,由岩土性能参数分析计算了切削刀具的受力,分别计算出刀盘上每把刀具所承受的力和扭矩。
论文系统分析了刀具的磨损原因和影响因素,并通过算例说明刀具寿命预测的分析方法,运用掘进参数检测滚刀的失效原理,滚刀磨损和失效的判断方法,介绍了刀具失效的常用判断方法,并给出了提高刀具寿命的建议。
运用PRO/E设计软件对盾构机模拟试验台的主要组件进行了结构设计,利用有限元分析软件ANSYS对主轴和切削刀具工作过程中所受的剪切力进行了有限元分析,为刀具的选择、安全系数的选取等提供了重要参考。
Shield method is a way of tunneling in soft or rock,it has many advantages,such as high speed,high precision,small vibration,low noise,has little impact on the surrounding environment,etc.As a representative of the most advanced tunneling techniques of today,tunnel boring method is applied very widely both at home and abroad.Shield tunneling machine is the main equitment of this new method,and the shield cutter and the cutter pan are the main tunneling part of the tunnel boring machine and play a very important role in tunnel boring construction.When tunneling in stratum,the abrasiong of shield cutters is serious,meanwhile the cutter bits are easily chip and scale.If such situations occur,the cutter torque will become higher and the shield will hard to advance.Therefore,it is of great signigicance to research on reducing the abrasion of cutters.
A new developed shield tunneling test system was introduced by this thesis.This test system inclueded test saddle,soil box,cutting head conveyer system,hydraulic system,etc.The test system was used for excavating experiments in different soil and rock,and the results of the experiment will be used to support for better tunneling organization.
Based on parameters obtained by theoretical study,the overall mechanical system was designed.Parts such as cutter head,driven system,trust system,conveyer system and soil box all designed through calculation.The hydraulic system was also designed through detailed calculation.All standard patrts involved in the test system included hydraulic component,gear box and sensors were selected by calculation.
This thesis based on soil and rock mechanics,studied the cutting mechanism of the different shield cutters in accordance with the different soil bodies,based on the knowledge of soil body performance and the simulation test of tunnel boring machine through different soil bodies. A theoreticalmodel was proposed based on the systematic analysis of cutter head torque in shield tunneling. Formulae of calculating torque components in this model were deduced.Forces on cutters when cutting soil or rock were analysed and calculated based on soil and rock mechanics.Furthermore,the force and torque of each cutter was calculated.
The abrasion reasons and influencing factors of all kinds of cutters were analyzed in this thesis.The cutters life were analysed according to calculating.General approaches for estimating the cutter wear,the principle of estimating the cutter wear and case studies are also introduced.Suggestions were given to increase cutters life.
In the use of three-dimensional designed software Pro/ENGINEER design the main parts of the shield tunneling machine simulated bedstand equipment. At last analyse the shearing force of principal axis and cutters by finite element analysis software ANSYS. By analysis the results, important reference for the structure and safety factor choose of cutters was provided.
引文
[1]李喜莲.盾构刀盘驱动液压系统及功率自适应控制方法研究[D].浙江:浙江大学.2007年
[2]盾构技术谱写地下空间开发新篇章[J].岩土工程界.2005年.第8卷(1).13-14
[3]置志新,殷琨.盾构技术在我国地下空间开发中的利用和新发展[J].建筑技术开发.2006年.第33卷(8).161-162
[4]丁凯.盾构机的技术特点分析[J]。筑路机械与施工机械。2006年.第23卷(5).8-10
[5]吴克利.国内外隧道掘进机械发展概述[J].重工与起重技术.2005年.第1期.29-32
[6]陈丹,袁大军,张弥.盾构技术的发展与应用[J].现代城市轨道交通.2005年.第5期.25-29
[7] Peter Darling. Steep tunneling for EPBM under the Avon Estuary[J]. Tunnels&Tunneling,January ,1993
[8]房猛.盾构推进机构电液控制系统的研究[D].杭州:浙江大学,2003
[9] D.T.C.Yao,j.H.Gou,and C.Chao Earth Pressure On Linings of Shield Tunnelling[J].Underground Construction and Ground Movement.2006.3.264-271
[10] J.Du,H.W.Huang,X.Y.and F.S.Zhang Research of the Effect of Permittivity on the Result of GPR Detection Grouting Material behind Shield Tunnel Segment[J].Underground Construction and Ground Movement.2006年.120-127
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[24]何伦.盾构施工工艺及刀秀刀具切削机理的研究[D].华南理工大学.2003年
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[34]蒋建敏,赵学彬,贺定勇,韩文政,邹积波.北京地区盾构机刀具失效分析及再制造研究[J].中国表面工程19卷第3期2006年6月
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[2]盾构技术谱写地下空间开发新篇章[J].岩土工程界.2005年.第8卷(1).13-14
[3]置志新,殷琨.盾构技术在我国地下空间开发中的利用和新发展[J].建筑技术开发.2006年.第33卷(8).161-162
[4]丁凯.盾构机的技术特点分析[J]。筑路机械与施工机械。2006年.第23卷(5).8-10
[5]吴克利.国内外隧道掘进机械发展概述[J].重工与起重技术.2005年.第1期.29-32
[6]陈丹,袁大军,张弥.盾构技术的发展与应用[J].现代城市轨道交通.2005年.第5期.25-29
[7] Peter Darling. Steep tunneling for EPBM under the Avon Estuary[J]. Tunnels&Tunneling,January ,1993
[8]房猛.盾构推进机构电液控制系统的研究[D].杭州:浙江大学,2003
[9] D.T.C.Yao,j.H.Gou,and C.Chao Earth Pressure On Linings of Shield Tunnelling[J].Underground Construction and Ground Movement.2006.3.264-271
[10] J.Du,H.W.Huang,X.Y.and F.S.Zhang Research of the Effect of Permittivity on the Result of GPR Detection Grouting Material behind Shield Tunnel Segment[J].Underground Construction and Ground Movement.2006年.120-127
[11]胡国良.盾构模拟试验平台电液控制系统关键技术研究.[D].杭州:浙江大学.2006年
[12]李贤妮盾构掘进试验系统的研制[D].北京:北京交通大学.2007年
[13]濮良贵纪明刚.机械设计[M].高等教育出版社.2001年,363.
[14]陈宁,司忠志.盾构螺旋输送机液压系统设计[J].浙江科技学院学报.2004年.第16卷(3).164-166
[15]胡国良,龚国芳,杨华勇,刑彤.盾构螺旋输送机液压驱动及控制系统[J].液压与气动.2004年.第12期.33-35
[16]傅德明,李向红,刘计山.大型多功能盾构掘进模拟试验台的研制[J].工程机械.2005(12).14-17
[17]胡国良.盾构模拟试验平台电液控制系统关键技术研究[D].浙江:浙江大学.
[18]蔡河山.土压平衡盾构液压传动控制系统浅析—刀盘驱动液压传动控制系统[J].液压与气动.2003年(8):30-31
[19]于颖,徐宝富等.软土地基土压平衡盾构切削刀盘扭矩的计算[J].中国工程机械学报.2004(7 ): 314-318
[20]何於琏.盾构机模拟试验台中的刀盘驱动液压系统[J].矿山机械.2006年.第34卷(5).30-31
[21]胡显鹏.砂卵石地层土压平衡盾构掘进刀具磨损研究[D].北京:北京交通大学.2006年
[22]何其平.土压平衡盾构刀盘结构探讨[J].工程机械2003(11)
[23]管会生,高波.盾构切削刀具寿命的计算[J].工程机械2006 (1)
[24]何伦.盾构施工工艺及刀秀刀具切削机理的研究[D].华南理工大学.2003年
[25]王化更.液压缸直接驱动盾构刀盘系统结构优化及控制研究[D].上海:同济大学.2006年
[26]管会生,高波.盾构刀盘扭矩估算的理论模型[J].西南交通大学学报,2008,43(2):214-217
[27]富昭治郎.建筑机械学.[M](日)鹿岛研究所出版会,2001年
[28]刘战强,艾兴.高速切削刀具磨损寿命的研究[J].工具技术2001(35)12
[29]孙德强,延长刀具使用寿命方法的探讨[J].职业教育研究(2005) 10
[30]杨平.浅谈刀具磨损与刀具的使用寿命[J].重庆职业技术学院学报(2005)10
[31]胡炳坤主编,金属切削工艺学[M].北京:中国铁道出版社.1991
[32]张国京,北京地区土压式盾构刀具的适应性分析[J].市政技术,2005 (23)
[33]陆剑中,孙家宁主编,金属切削原理与刀具[M].北京:机械工业出版社.1984
[34]蒋建敏,赵学彬,贺定勇,韩文政,邹积波.北京地区盾构机刀具失效分析及再制造研究[J].中国表面工程19卷第3期2006年6月
[35]张凤祥,朱合华,傅德明编著.盾构隧道[M].北京:人民交通出版社, 2004
[36]张厚美.复合地层中盾构刀具磨损的检测方法研究[J].盾构掘进机设计制造.
[37] Nelson P. P.,Ingraffea A. R.,O'Rourke T. D.,1985,"Technical Note:TBM per- formance prediction a sing rock fracture parameters",Int. J. of Rock Mech. &Mining Sci. &Geomech. V.22,No. 3,PP" 189-192
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