In order to accurately predict the service life of the hob in the rock-breaking process of Tunnel Boring Machine(TBM) to improve the boring efficiency and determine the time of changing the hob, this study analyzed the rock-breaking mechanism of the disk hob and established the calculation model of the normal force of rock-breaking hob of TBM based on the shear and tensile failure mechanism. The Rabinowicz abrasive wear model was improved based on the dense core effect to establish the wear rate and life prediction model of TBM disc cutters considering dense core effect and compression-shear failure mode. The engineering applicability of the prediction model proposed in this study was verified by the comparing the prediction results with the existing theoretical model calculation results, numerical simulation results and on-site monitoring results. The results show that the predicted values of this model are closer to the measured values in the engineering field. Compared with the existing theoretical model, the average prediction accuracies of cutter wear rate and cutter life are improved by 9.1% and 11.7% respectively, which effectively demonstrates the necessity of comprehensively considering the dense core effect and compression-shear failure mode in the calculation of TBM cutters breaking rock. The cutter wear rate and life index can be used as reliable indexes for evaluating the cutter wear characteristics during the rock breaking process of TBM, which can provide theoretical guidance for the design and timing of cutters change program in TBM tunnel and other similar projects.
SunJian, ChenLiang, MaHong-su, et al. Research status and prospect of assisting rock breaking methods for TBM tunnelling in extremely hard rocks[J]. World Nuclear Geoscience, 2024, 41(1): 141-163.
ZhangMeng-qi, GouBin, DengYu, et al. Cutting performance and contact behavior of a novel TBM cutter with surface spiral grooves[J]. Journal of Mechanical Engineering, 2023, 59(5): 259-270.
ZhaiShu-fang, DuHong-kun, YueQi-chao, et al. Analysis of the optimal penetration of disc cutter in rock breaking based on characteristic particle size[J]. Modern Tunnelling Technology, 2023, 60(4): 147-152, 162.
LiGuo-long, LiBiao, JiangLin, et al. Hob wear recognition method based on HHT and IPSO-RBF neural network[J]. Journal of Jilin University(Engineering and Technology Edition), 2020, 50(6): 1998-2009.
CaoJiu-lei, YuJin, ZhangZhu-qing, et al. Force calculation model of TBM disc cutter based on rock breaking mode[J]. Journal of China Coal Society, 2023, 48(8): 3300-3311.
[11]
HuX K, DuC L, LiuS Y, et al. Three-dimensional numerical simulation of rock breaking by the tipped hob cutter based on explicit finite element[J]. IEEE Access, 2019, 7: 86054-86063.
[12]
LiX, WuJ Q, HuoP. Prediction model for the teeth hob cutter of tunnel boring machines in high-content quartzite strata[J]. KSCE Journal of Civil Engineering, 2023, 27(1): 371-383.
[13]
SheL, LiY L, WangC, et al. Prediction of TBM disc cutter wear based on field parameters regression analysis[J]. Geomechanics and Geoengineering, 2023, 35(6): 647-663.
WangChao, QiaoShi-fan, LiuHong-zhong. Research on force calculation model of hob in TBM rock breaking progress[J]. Engineering Mechanics, 2021, 38(10): 54-63.
ZhangBin-rong, GuanHui-sheng, TanXiao-feng, et al. Dynamic model and vibration analysis of TBM edge-cutter based on MATLAB/Simulink[J]. Tunnel Construction, 2020, 40(6): 833-839.
[18]
RostamiJ. Development of a force estimation model for rock fragmentation with disc cutters through theoretical modeling and physical measurement of crushed zone pressure[D]. Golden:Colorado School of Mines, 1997.
[19]
BrulandA. Hard rock tunnel boring[D]. Trondheim:Norwegian University of Science and Technology, 1998.
[20]
WangL H, KangY L, ZhaoX J, et al. Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis[J]. Tunnelling and Underground Space Technology, 2015, 50(1): 324-333.
[21]
YangY D, HongK R, SunZ C, et al. The derivation and validation of TBM disc cutter wear prediction model[J]. Geotechnical and Geological Engineering, 2018, 36(6): 3391-3398.
[22]
SuW L, LiX G, JinD L, et al. Analysis and prediction of TBM disc cutter wear when tunneling in hard rock strata: a case study of a metro tunnel excavation in Shenzhen, China[J]. Wear, 2020, 446-447(4): No.203190.
SheLei, ZhangShe-rong, HeSun-wen, et al. Prediction model for TBM disc cutter wear based on dense core theory[J]. Chinese Journal of Geotechnical Engineering, 2022, 44(5): 970-978.
[25]
KeC C, ChenC S, KuC Y, et al. Modeling crack propagation path of anisotropic rocks using boundary element method[J]. International Journal for Numerical and Analytical Methods in Geomechanics, 2009, 33(9): 1227-1253.
[26]
ZhangZ H, AqeelM, LiC, et al. Theoretical prediction of wear of disc cutters in tunnel boring machine and its application[J]. Journal of Rock Mechanics and Geotechnical Engineering, 2019, 11(1): 111-120.
ZhaoJian, LiHai-bo. Estimating the dynamic strength of rock using Mohr-Coulomb and Hoek-Brown criteria[J]. Chinese Journal of Rock Mechanics and Engineering, 2003, 22(2): 171-176.
[29]
RabinowiczE. Friction and Wear of Materials[M]. New York: John Wiley & Sons, 1995.
ZhaoHai-ming, ShuBiao, XiaYi-min, et al. Study of wear prediction for TBM cutter based on abrasive wear model[J]. Journal of Railway Science and Engineering, 2014, 11(8): 152-158.
[32]
BrulandA. Hard rock tunnel boring[D]. Trondheim:Norwegian University of Science and Technology, 1998.
[33]
MaL, LowS R, FinkJ. Effects of steel and tungsten carbide ball indenters on Rockwell hardness measurements[J]. Journal of Testing and Evaluation, 2006, 34(3): 187-199.
ShiZhen-ming, LiuLiu, GuanSheng-gong, et al. Study on visualized detector of shield machine forecabin equipment and its application[J]. Journal of Highway and Transportation Research and Development, 2019, 36(1): 109-116.
LiuJie, DengLi-ying, NiZhi-hua, et al. Method of predicting TBM disc cutter's wear and service life[J]. Journal of Machine Design, 2024, 41(10): 59-66.