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Prediction Model of TBM Disc Cutter Wear During Tunnelling in Heterogeneous Ground

  • Dong-Jie Ren
  • Shui-Long Shen
  • Arul Arulrajah
  • Wen-Chieh Cheng
Original Paper
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Abstract

When shield tunnelling is constructed in complex geological conditions using a tunnel boring machine, the disc cutter in the cutterhead easily wears to the failure state, particularly when the ground conditions are heterogeneous. This paper summarises the failure modes of the disc cutter in heterogeneous ground conditions into three categories, based on the observed wear data from field: (1) uniform disc cutter wear, (2) non-uniform disc cutter wear, and (3) breakage of cutter ring. Subsequently, the stress state of a disc cutter in the heterogeneous ground was analysed and the effective factors were investigated. The relationships between friction energy during cutting, working status of the machine and the characteristics of the geological conditions were evaluated. Based on the stress analysis and friction energy, a prediction model was proposed. The proposed model was applied to two field case studies: pertaining to uniform and mixed-face ground conditions, for which the empirical coefficient k for energy transfer was also determined. The preliminary results from this research indicated that the proposed model was valid for both homogeneous and heterogeneous ground conditions. Further case studies provided by co-operators are expected to improve the effectiveness of the proposed model.

Keywords

Prediction model Friction energy Disc cutter wear Heterogeneous ground 

Abbreviations

a, b, c

Coefficient

ar

Acceleration in radius direction of single disc cutter

CAI

Cerchar Abrasivity Index

Ef

Rock excavation volume per cutter wear extent

f

Friction force

Fd

Impact loading acting on the cutter ring

Fn

Thrust force of TBM

Fr

Normal reaction force

Ft

Rolling force induced by the cutterhead rotation

H0

Basic average cutter ring life (h)

Hh

Average cutter ring life (h)

k

Empirical coefficient between the friction energy and the cutter wear

kD

Correction factor for TBM diameter with regard to cutter ring life

kN

Correction factor of cutter amount

kQ

Correction factor for abrasive minerals

krpm

Correction factor for varying cutterhead velocity

l

Length of tunnel ring

n

Rotation speed of cutterhead

nd

Dynamic factor

N

Number of data points

Nr

Amount of tunnel rings

Ntbm

Actual number of cutters

Pr

Contact pressure

q

Predicted cutter wear of one single disc cutter after penetrating one ring’s distance

Q

Wear value obtained after replacing disc cutter

Equivalent wear value of disc cutter

r

Installation radius of the disc cutter on the cutterhead

R

Radius of disc cutter

Rc

Radius of cutterhead

s

Friction distance

Ss

Spacing of neighbouring disc cutters

t

Time of friction process

T

Torque of cutterhead

UCS

Unconfined compression strength

v

Penetration speed of TBM

vg

Specific ring weight loss

vt

Velocity in tangential direction of single disc cutter

w

Width of the cutter tip

W

Friction energy of each disc cutter

WFn

Cutter thrust force work

WFr

Cutter rolling force work

Wi

Friction energy consumption per ring

x

Wear value of non-uniform

z

Distance of interface from the centre of cutterhead

α

Frictional coefficient

σt

Tensile strength

Φ

Angle of contact area

ω

Angular velocity of disc cutter

ωc

Angular velocity of cutterhead

Notes

Acknowledgements

The research work described herein was funded by the National Basic Research Program of China (973 Program: 2015CB057806) and the National Nature Science Foundation of China (NSFC) (Grant no. 41672259). These financial supports are gratefully acknowledged.

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Copyright information

© Springer-Verlag GmbH Austria, part of Springer Nature 2018

Authors and Affiliations

  • Dong-Jie Ren
    • 1
    • 2
  • Shui-Long Shen
    • 1
    • 2
  • Arul Arulrajah
    • 3
  • Wen-Chieh Cheng
    • 1
    • 2
  1. 1.State Key Laboratory of Ocean Engineering, School of Naval Architecture, Ocean and Civil EngineeringShanghai Jiao Tong UniversityShanghaiChina
  2. 2.Collaborative Innovation Center for Advanced Ship and Deep-Sea Exploration (CISSE), Department of Civil EngineeringShanghai Jiao Tong UniversityShanghaiChina
  3. 3.Department of Civil and Construction EngineeringSwinburne University of TechnologyMelbourneAustralia

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