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Prediction model for disc cutter wear during hard rock breaking based on plastic removal abrasiveness mechanism

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Abstract

In this study, the correlation between the uniform wear volume of the disc cutter and the normal load is established based on a principle of microcutting plastic removal of abrasive wear. By introducing a calibration expression of the normal load for CSM model, the wear rate index and life index of a disc cutter are defined and derived; thus, a theoretical prediction model for rock-breaking wear of disc cutters is developed, and the quantitative relationship between the cutter wear index and various influencing factors is obtained. In addition, an orthogonal experimental design method is used to propose the criterion for the significance level of the parameters of the models. The results show that in the selection of actual tunneling parameters and the optimization design of the cutterhead, the values of the rock compressive strength, the rock brittleness index, the penetration depth, and the material hardness and the spacing of neighboring disc cutter should be the focus of parameter research. Furthermore, the validity and reliability of the developed models are validated by two hard rock tunnel engineering cases. Finally, the prediction models are applied to the under-construction project of Metro Line 12 in Shenzhen, China, and the parameter optimization measures to reduce disc cutter wear and prolong cutting life are proposed. A scheme for the inspection and replacement of disc cutters is also formulated. All the input parameters of the proposed model are easily accessible at the early stage of project construction, and the accuracy of the predictor is more than 80%. Therefore, it is a very practical tool for designers and constructors.

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Abbreviations

TBM:

Tunnel boring machine

CAI:

Cerchar abrasivity index

CSM:

Colorado School of Mines

EPB:

Earth pressure balance

D 0 :

Diameter of a disc cutter, m

S :

Spacing of disc cutters, m

T :

Blade width of a disc cutter, m

H :

Hardness of the cutter ring material

h :

Penetration depth of a disc cutter, m/rev

σ c :

The uniaxial compressive strength of rock, Pa

θ :

The half angle of the cone, rad

r :

The radius of the cone bottom, m

N :

Number of asperities on the surface of a material

F n :

The thrust of a disc cutter, N

σ s :

The yield strength of disc cutter ring material, Pa

x :

The penetration depth of an abrasive, m

s :

The sliding distance of the abrasive, m

V 0 :

The wear volume of the unit sliding distance, m3

K :

The probability number of abrasive grains

K s :

The wear coefficient of abrasive grains

F r :

The rolling force of a disc cutter, N

F s :

The lateral force of a disc cutter, N

F' :

The reaction force of rock, N

C :

The normalized coefficient of stiffness

φ :

The contact angle between a cutter and rock, rad

R 0 :

The radius of a disc cutter, m

P 0 :

The pressure of the broken zone, Pa

B i :

The brittleness index of rock

ψ :

The pressure distribution coefficient of the top edge of a cutter ring

σ t :

The tensile strength of rock, Pa

l :

The actual total cutting path of a disc cutter for 1 turn, m

V :

The cumulative wear volume of a disc cutter for 1 turn, m3

m :

The radial wear length of a disc cutter for 1 turn, m

ω :

The wear rate of a disc cutter index, mm/m

L :

The distance in a TBM tunneling, m

M :

The cumulative radial wear length of a cutter at L distance, m

R i :

The installation radius of a cutter on a cutterhead, m

λ :

The cutting life index of a disc cutter, m/μm

M max :

Limits of radial wear length of a disc cutter, m

u :

The cutting distance of a disc cutter at the maximum limit wear of the ring, m

L n(t c):

The number of the orthogonal test table

t :

The level number of factors

c :

The number of columns in the orthogonal table

n :

The total number of experiments

F j :

F-Test statistics of each factor

α :

Significance level

ω 1 :

The measured value of the wear rate of a disc cutter, mm/m

ω 2 :

The calculated value of the wear rate of a disc cutter, mm/m

η ω :

The difference rate between ω1 and ω2

λ 1 :

The measured value of the life index of a disc cutter, m/μm

λ 2 :

The calculated value of the life index of a disc cutter, m/μm

η λ :

The difference rate between λ1 and λ2

K ij :

The deviation of the jth-factor ith-level test results

L max :

The tunneling distance of a TBM within the wear limit, m

H f :

The rock excavation volume per cutter, m3/cutter.

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Acknowledgements

We gratefully wish to acknowledge the National Natural Science Foundation of China (No. 51779168 and 51979188), the National Key Research and Development Program of China (No. 2018YFC0406905), Tianjin science and technology leading enterprise cultivation major project (No. 17YDLJSF00010). In addition, all data involved are available in this manuscript.

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Authors and Affiliations

  1. School of Civil Engineering, Tianjin University, No. 135 Yaguan Road, Tianjin, 300072, China

    Lei She, She-rong Zhang, Chao Wang & Li-xin Wang

  2. State Key Laboratory of Hydraulic Engineering Simulation and Safety, Tianjin University, No. 135 Yaguan Road, Tianjin, 300072, China

    Lei She, She-rong Zhang, Chao Wang & Li-xin Wang

  3. China Water Resources Beifang Investigation, Design and Research Co. Ltd. (BIDR), Tianjin, 300222, China

    Zheng-qiao Wu & Lun-chuang Yu

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  1. Lei She
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  2. She-rong Zhang
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  3. Chao Wang
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  4. Zheng-qiao Wu
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Correspondence to Chao Wang.

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Highlights

• The correlation between the uniform wear volume of the disc cutter and the normal load is established based plastic removal abrasiveness.

• The quantitative relationship between the cutter wear rate or cutting life index and various influencing factors is developed.

• The criterion for the significance level of the parameters of the prediction model is proposed.

• An optimization scheme for the inspection and replacement of disc cutters is also formulated in field.

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She, L., Zhang, Sr., Wang, C. et al. Prediction model for disc cutter wear during hard rock breaking based on plastic removal abrasiveness mechanism. Bull Eng Geol Environ 81, 432 (2022). https://doi.org/10.1007/s10064-022-02915-5

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