Abstract
Partial wear is one of the fatal abnormal wears, which may pose a threat to the cutterhead or even the driving system. Considering the randomness of partial wear, the real-time detection and early warning of partial-wear states are very important, but it requires a deep understanding of the mechanism and characteristics of the interaction between the partial-worn cutter and rock. In this study, rock-cutting experiments are conducted on a cutter under partial wear via multifunctional cutter test machine. The key dynamic parameters of the partial-worn cutter (e.g., loading history during rock cutting) are analyzed. The influence of partial wear on cutter-rock contact behavior is examined with a particle flow discrete element model. The results show that after partial wear, the contact area of the cutter can be divided into two parts: an arc region and a linear region. Reduction in the projected area of the arc region decreases the normal force of the cutter. The appearance of the linear region and changes in the friction type between the cutter and rock from rolling to sliding increase the tangential force. The partial-worn cutter still has rock-breaking ability, but the linear contact region prolongs the working time of the cutter and generates more rock powder, ultimately increasing its rock-cutting specific energy. The results of this work reveal changes in rock-cutting characteristics of partial-worn cutters, providing workable theoretical support for the detection and early warning of partial wear in cutters.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Breugnot A, Lambert S, Villard P, Gotteland P (2016) A discrete/continuous coupled approach for modeling impacts on cellular geostructures. Rock Mech Rock Eng 49:1831–1848. https://doi.org/10.1007/s00603-015-0886-8
Cao HM, Zhou X, Li XY, Lu K (2017) Friction mechanism in the running-in stage of copper: from plastic deformation to delamination and oxidation. Tribol Int 115:3–7. https://doi.org/10.1016/j.triboint.2017.05.027
Cook NGW, Hood M, Tsai F (1984) Observations of crack growth in hard rock loaded by an indenter. Int J Rock Mech Mining Sci 21:97–107. https://doi.org/10.1016/0148-9062(84)91177-X
Ding X, Zhang L, Zhu H, Zhang Q (2014) Effect of model scale and particle size distribution on PFC3D simulation results. Rock Mech Rock Eng 47:2139–2156. https://doi.org/10.1007/s00603-013-0533-1
Duan W, Zhang L, Zhang M et al (2022) Numerical and experimental studies on the effects of the TBM cutter profile on rock cutting. KSCE J Civ Eng 26:416–432. https://doi.org/10.1007/s12205-021-2111-5
Ghamgosar M, Duffield S, Erarslan N (2018) Progressive damages in hard rock by utilising an oscillating undercut technology. In: Geomechanics and Geodynamics of Rock Masses - Selected Papers from the 2018 European Rock Mechanics Symposium, Eurock. pp 471–477
Gong QM, She QR, Ding Y (2012) Abrasivity tests of marbles and cutter wear analysis of TBM: headrace tunnels of Jinping II hydropower station. Beijing Gongye Daxue Xuebao/journal of Beijing University of Technology 38:1196–1201
Guixiang Z, Like HE, Qing T et al (2019) Experimental study on the rock breaking characteristics of TBM disc cutter under saturated condition. J Railw Sci 16:3126–3133. https://doi.org/10.19713/j.cnki.43−1423/u.2019.12.028
Hassanpour J, Rostami J, Tarigh Azali S, Zhao J (2014) Introduction of an empirical TBM cutter wear prediction model for pyroclastic and mafic igneous rocks; a case history of Karaj water conveyance tunnel. Iran Tunnel Undergr Space Technol 43:222–231. https://doi.org/10.1016/j.tust.2014.05.007
Hongxiang, Jiang, Changlong D, Songyong L, Kuidong G (2015) Numerical analysis on damage field of rock fragmentation with water jet. J Central South Univ (Science and Technology) 46:287–294. https://doi.org/10.11817/j.issn.1672
Hu M, Zhang B, Li B et al (2022) TBM-cutter rock-breaking effect and mechanism considering different cutting sequences. Bull Eng Geol Environ 81. https://doi.org/10.1007/s10064-022-02576-4
Karami M, Zare S, Rostami J (1987) Study of Common Wear Prediction Models for Hard Rock TBM Disc Cutters and Comparison with Field Observation in Kerman Water Conveyance Tunnel. https://doi.org/10.1007/s10064-020-01987-5/Published
Ko TY, Lee SS (2020) Effect of rock abrasiveness on wear of shield tunnelling in bukit timah granite. Appl Sci 10:3231. https://doi.org/10.3390/app10093231
Lazarova E, Krypa V, Ivanicova L (2013) Comparability study of selected factors of assessment of the full-face tunnelling process. International Multidisciplinary Scientific GeoConference: SGEM p. 303–308
Li J, Nie Y, Fu K et al (2018) Experiment and analysis of the rock breaking characteristics of disc cutter ring with small edge angle in high abrasive grounds. J Brazilian Soc Mech Sci Eng 40. https://doi.org/10.1007/s40430-018-1422-z
Liang L, Helin F (2000) Rock breaking mechanism by TBM and modification to pan knife ring. J China Railw Soc 11:5–7
Lijun S, Jinshan S, Wenbo L (2009) Research on numerical simulation of rock fragmentation by TBM cutters using particle flow method. Rock Soil Mech 7598:2823–2829
Lin L, Mao Q, Xia Y et al (2017) Experimental study of specific matching characteristics of tunnel boring machine cutter ring properties and rock. Wear 378–379:1–10. https://doi.org/10.1016/j.wear.2017.01.072
Lin L, Xia Y, Mao Q, Zhang X (2018) Experimental study on wear behaviors of TBM disc cutter ring in hard rock conditions. Tribol Trans 61:920–929. https://doi.org/10.1080/10402004.2018.1442895
Liu Q, Deng P (2020) Numerical study of rock fragmentation process and acoustic emission by FDEM based on heterogeneous model. Math Problems Eng 2020. https://doi.org/10.1155/2020/2109584
Liu X, Xu M, Qin P (2019) Joints and confining stress influencing on rock fragmentation with double disc cutters in the mixed ground. Tunn Undergr Space Technol 83:461–474. https://doi.org/10.1016/j.tust.2018.08.051
Liu Z, Zheng M, Yan X et al (2020) Changing behavior of friction coefficient for high strength bolts during repeated tightening. Tribol Int 151:106486. https://doi.org/10.1016/j.triboint.2020.106486
Liu ZW, Wang BQ, Shang W (2017) Study of wireless detection system of shield cutter wear based on ultrasonic. Tunnel Construction 37:1469–1474
Pan Y, Liu Q, Liu Q et al (2020) Full-scale linear cutting tests to check and modify a widely used semi-theoretical model for disc cutter cutting force prediction. Acta Geotech 15:1481–1500. https://doi.org/10.1007/s11440-019-00852-4
Ping, Cao, Qibin, Lin, Kaihui, Li, Dongya, Han (2017) Effects of joint angle and joint space on rock fragmentation efficiency by two TBM disc cutters. Zhongnan Daxue Xuebao (Ziran Kexue Ban)/J Central South Univ (Science and Technology) 48:1293–1299. https://doi.org/10.11817/j.issn.1672-7207.2017.05.023
Potyondy DO, Cundall PA (2004) A bonded-particle model for rock. Int J Rock Mech Min Sci 41:1329–1364. https://doi.org/10.1016/j.ijrmms.2004.09.011
Pourhashemi SM, Ahangari K, Hassanpour J, Eftekhari SM (2021) Evaluating the influence of engineering geological parameters on TBM performance during grinding process in limestone strata. Bull Eng Geol Env 80:3023–3040. https://doi.org/10.1007/s10064-021-02134-4
Qing De S, Zhi Ming W, Jun Quan Y, Wen Hua Z (2005) A disquisition on breaking mechanism of high pressure jet impacting on rock. Yantu Lixue/Rock Soil Mech 26:978–982. https://doi.org/10.16285/j.rsm.2005.06.033
Ren D, Shen S, Arulrajah A, Cheng W (2018) Prediction model of TBM disc cutter wear during tunnelling in heterogeneous ground. Rock Mech Rock Eng 51:3599–3611. https://doi.org/10.1007/s00603-018-1549-3
Ren D, Shen S, Yuan D, Chai J (2017) Prediction model for TBM disc cutter wear in mixed-face ground condition. DEStech Transact Mater Sci Eng 69:116–124. https://doi.org/10.12783/dtmse/ictim2017/9961
Snyder LL, Williams RI (1991) Recent development in the design of hard rock tunnel boring machines for the mining industry. In: High Level Radioactive Waste Management. Tunnelling Association of Canada Annual Publication pp 1622–1635
Su W, Li X, Jin D et al (2020) 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. https://doi.org/10.1016/j.wear.2020.203190
Sun R, Mo J, Zhang M et al (2022) Cutting performance and contact behavior of partial-wear TBM disc cutters: a laboratory scale investigation. Eng Fail Anal 137:106253. https://doi.org/10.1016/j.engfailanal.2022.106253
Tan Q, Yi L, Xia Y (2018) Performance prediction of TBM disc cutting on marble rock under different load cases. KSCE J Civ Eng 22:1466–1472. https://doi.org/10.1007/s12205-017-1048-1
Tan Q, Zhang G, Xia Y, Li J (2015) Differentiation and analysis on rock breaking characteristics of TBM disc cutter at different rock temperatures. J Central South Univ 22:4807–4818. https://doi.org/10.1007/s11771-015-3032-6
Wang F, Zhou D, Zhou X et al (2020) Rock breaking performance of TBM disc cutter assisted by high-pressure water jet. Appl Sci (Switzerland) 10. https://doi.org/10.3390/APP10186294
Yu H, Tao J, Huang S et al (2021) A field parameters-based method for real-time wear estimation of disc cutter on TBM cutterhead. Autom Constr 124:103603. https://doi.org/10.1016/j.autcon.2021.103603
Yu Q, Long W, Yang X, Zhao Y (2019) Effects of heat treatment process with different hardness gradients on microstructure and mechanical properties of shield cutter ring. Hot Work Technol 48:104–107. 10.14158/j
Yuan T, Yadong X, Feng Z (2018) Rock breaking mechanism of TBM cutters for rocks with different brittleness indexes under confining pressure condition. Modern Tunnel Technol 55:48–56
Zhang G, Xiao C (2018) Analysis of stress distribution of disc cutter under different tunnelling parameters. Aust J Mech Eng 16:49–53. https://doi.org/10.1080/1448837X.2018.1545472
Zhang H (2011) Mechanical analysis of TBM disc cutter damage mechanism and its application. Modern Tunnel Technol 48:55–85. https://doi.org/10.13807/j.cnki.mtt.2011.01.018
Zhang M, Zhou Z (2020) Semi-analytical contact model for analyzing rock fragmentation induced by an indenter. Tunnel Undergr Space Technol 103:103496. https://doi.org/10.1016/j.tust.2020.103496
Zhang X, Lin L, Xia Y et al (2018) Experimental study on wear of TBM disc cutter rings with different kinds of hardness. Tunn Undergr Space Technol 82:346–357. https://doi.org/10.1016/j.tust.2018.08.050
Zhao H, Shu B, Xia Y, Zheng W (2014) Study of wear prediction for TBM cutter based on abrasive wear model. J Railw Sci Eng 11:152–158
Funding
Mr. Zhang and Mr. Mo received support from the National Natural Science Foundation of China (Grant No. 52005419 and U22A20181), Key Research and Development Project of Sichuan Province (21ZDYF3658), and Major Scientific and Technological Innovation Projects in Chengdu (2019-YF08-00100-GX).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Sun, R., Mo, J., Zhang, M. et al. Interaction between partial-worn TBM cutters and rocks: experimental and numerical investigation. Bull Eng Geol Environ 82, 111 (2023). https://doi.org/10.1007/s10064-023-03127-1
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s10064-023-03127-1