Abstract
Teeth hob cutter is widely used in cutting through hard rock. Cutter wear is inevitable during the strata with a large quartzite content, and excessive wear can lead to a decrease in tunneling efficiency and increase construction risks. Therefore, the importance of predicting the teeth hob cutter wear accurately and arranging the cutter change plan can never be overemphasized. In this paper, the rock breaking mechanism of teeth hob cutter was first analyzed. Based on this, combined with the theory of metal tribology theory, the wear prediction model for teeth hob cutters in high-content quartzite strata was derived. To verify the accuracy of the prediction model, the teeth hob cutter wear data for two cases were measured, which were collected from a cross-river shield tunnel project in Guangdong, China. Based on the observed wear data, it is found that the relative error of predicted wear and actual measurement was below 10%. The result shows that the prediction model can accurately reflect the real wear situation of teeth hob cutter in high-content quartzite strata.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Amoun S, Sharifzadeh M, Shahriar K, Rostami J, Azali ST (2017) Evaluation of tool wear in EPB tunneling of Tehran metro, line 7 expansion. Tunnelling and Underground Space Technology 61:233–246, DOI: https://doi.org/10.1016/j.tust.2016.11.001
Chao LC, Tsay CB (2011) Tooth flank, undercutting and tooth pointing of spherical gears. Mechanism and Machine Theory 46:534–543, DOI: https://doi.org/10.1016/j.mechmachtheory.2010.11.007
Di H, Zhou S, Yao X, Tian Z (2021) In situ grouting tests for differential settlement treatment of a cut-and-cover metro tunnel in soft soils. Bulletin of Engineering Geology and the Environment 80(3), DOI: https://doi.org/10.1007/s10064-021-02276-5
Elbaz K, Shen SL, Zhou AN, Yin ZY, Lyu HM (2020) Prediction of disc cutter life during shield tunneling with AI via the incorporation of a genetic algorithm into a GMDH-type neural network. Engineering 7(2):238–251, DOI: https://doi.org/10.1016/j.eng.2020.02.016
Guo ZW, Deng R, Zhang WT (2019) Non-spherical single cone bit tooth failure analysis and tooth load test. Engineering Failure Analysis 105:1–11, DOI: https://doi.org/10.1016/j.engfailanal.2019.06.090
Hassanpour J (2018) Development of an empirical model to estimate disc cutter wear for sedimentary and low to medium grade metamorphic rocks. Tunnelling and Underground Space Technology 75:90–99, DOI: https://doi.org/10.1016/j.tust.2018.02.009
He JA, Wang YW (2001) Material wear and wear materials. Northeastern University, Shenyang, China (in Chinese)
Hu XK, Du CL, Liu SY, Liu ZQ (2019) Three-dimensional numerical simulation of rock breaking by the tipped hob cutter based on explicit finite element. IEEE Access (99):1–1, DOI: https://doi.org/10.1109/ACCESS.2019.2925427
Hu XK, Jiang HX, Du CL (2020) Finite element method for prediction of rock breaking performance of the tipped hob with different tooth profiles. IEEE Access (99):1–1, DOI: https://doi.org/10.1109/ACCESS.2020.2980427
Huang KL, Ai ZJ, Yang YX, Xie ZL (2019) The improved rock breaking efficiency of an annular-groove PDC bit. Journal of Petroleum Science and Engineering 172:425–435, DOI: https://doi.org/10.1016/j.petrol.2018.09.079
Küpferle J, Zizka Z, Schoesser B, Röttger A, Alber M, Thewes M, Theisen W (2018) Influence of the slurry-stabilized tunnel face on shield TBM tool wear regarding the soil mechanical changes — experimental evidence of changes in the tribological system. Tunnelling and Underground Space Technology 74:206–216, DOI: https://doi.org/10.1016/j.tust.2018.01.011
Li YT, Di HG, Yao QY, Fu LL, Zhou SH (2020a) Prediction model for disc cutter wear of tunnel boring machines in sandy cobble strata. KSCE Journal of Civil Engineering 24(3):1010–1019, DOI: https://doi.org/10.1007/s12205-020-1631-8
Li X, Di HG, Zhou SX, Huo P, Huang Q (2021) Effective method for adjusting the uplifting of shield machine tunneling in upper-soft lower-hard strata. Tunnelling and Underground Space Technology incorporating Trenchless Technology Research 115, DOI: https://doi.org/10.1016/J.TUST.2021.104040
Li X, Zhou SH, Di HG (2020b) Observed ground pressure acting on the lining of a large-diameter shield tunnel in sandy stratum under high water pressure. Advances in Civil Engineering 2020:1–12, DOI: https://doi.org/10.1155/2020/3091528
Li X, Zhou SH, Di HG, Wang PX (2018) Evaluation and experimental study on the sealant behaviour of double gaskets for shield tunnel lining. Tunnelling and Underground Space Technology 75:81–89, DOI: https://doi.org/10.1016/j.tust.2018.02.004
Liu QS, Liu JP, Pan YC, Zhang XP, Peng XX, Gong QM, Du LJ (2017) A wear rule and cutter life prediction model of a 20-in. TBM cutter for granite: A case study of a water conveyance tunnel in China. Rock Mechanics and Rock Engineering 50(5):1303–1320, DOI: https://doi.org/10.1007/s00603-017-1176-4
Majeed Y, Abu Bakar MZ (2019) Effects of variation in the particle size of the rock abrasion powder and standard rotational speed on the NTNU/SINTEF abrasion value steel test. Bulletin of Engineering Geology and the Environment 78:1573–1554, DOI: https://doi.org/10.1007/s1006-017-1211-4
Munoz H, Taheri A, Chanda E (2016) Rock cutting characteristics on soft-to-hard rocks under different cutter inclinations. International Journal of Rock Mechanics and Mining Sciences 87:85–89, DOI: https://doi.org/10.1016/j.ijrmms.2016.05.014
Petrica M, Badisch E, Peinsitt T (2013) Abrasive wear mechanisms and their relation to rock properties. Wear 308:86–94, DOI: https://doi.org/10.1016/j.wear.2013.10.005
Qin CJ, Shi G, Tao JF, Yu HG, Jin YR, Lei JB, Liu CL (2021) Precise cutterhead torque prediction for shield tunneling machines using a novel hybrid deep neural network. Mechanical Systems and Signal Processing 151(6):107386, DOI: https://doi.org/10.1016/j.ymssp.2020.107386
Rabinowicz E, Tanner RI (1995) Friction and wear of materials. Journal of Applied Mechanics 33:606–611, DOI: https://doi.org/10.1115/1.3625110
Ren DJ, Shen SL, Arulrajah A, Cheng WC (2018) Prediction model of TBM disc cutter wear during tunnelling in heterogeneous ground. Rock Mechanics and Rock Engineering 51:3599–3611, DOI: https://doi.org/10.1007/s00603-018-1549-3
Su WL, Li XG, Jin DL, Yang Y, Qin RC, Wang XY (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. Wear 446–447, DOI: https://doi.org/10.1016/j.wear.2020.203190
Tan Q, Yi L, Xia YM (2018) Performance prediction of TBM Disc cutting on marble rock under different load cases. KSCE Journal of Civil Engineering 22(4):1466–1472, DOI: https://doi.org/10.1007/s12205-017-1048-1
Tan Q, Zhang K, Zhou ZL, Xia YM (2010) Numerical simulation and experimental observation of rock cracks under action of spherical tooth hob cutter. Chinese Journal of Rock Mechanics and Engineering 2010 29(1):163–169
Trezona RI, Allsopp DN, Hutchings IM (1999) Transitions between two-body and three-body abrasive wear: Influence of test conditions in the microscale abrasive wear test. Wear S225–229:205–214, DOI: https://doi.org/10.1016/S0043-1648(98)00358-5
Wang LH, Kang YL, Zhao XJ, Zhang Q (2015) Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis. Tunnelling and Underground Space Technology 50:324–333, DOI: https://doi.org/10.1016/j.tust.2015.08.003
Wang LH, Li HP, Zhao XJ, Zhang Q (2017) Development of a prediction model for the wear evolution of disc cutters on rock TBM cutterhead. Tunnelling and Underground Space Technology 67:147–157, DOI: https://doi.org/10.1016/j.tust.2017.05.003
Wang X, Su O (2019) Specific energy analysis of rock cutting based on fracture mechanics: A case study using a conical pick on sandstone. Engineering Fracture Mechanics 213:197–205, DOI: https://doi.org/10.1016/j.engfracmech.2019.04.010
Wang RR, Wang YX, Li JB, Jing LJ, Zhao GZ, Nie LC (2020) A TBM cutter life prediction method based on rock mass classification. KSCE Journal of Civil Engineering 24(9):2749–2087, DOI: https://doi.org/10.1007/s12205-020-1511-2
Yang YD, Hong KR, Sun ZC, Chen K, Li FY, Zhou JJ, Zhang B (2018a) The derivation and validation of TBM disc cutter wear prediction model. Geotechnical and Geological Engineering 36:3391–3398, DOI: https://doi.org/10.1007/s10706-018-0540-9
Yang H, Liu J, Liu B (2018b) Investigation on the cracking character of jointed rock mass beneath TBM disc cutter. Rock Mechanics and Rock Engineering 51:1263–1277, DOI: https://doi.org/10.1007/s00603-017-1395-8
Zhang XH, Lin LK, Xia YM, Tan Q, Zhu ZM, Mao QS, Zhou M (2018) Experimental study on wear of TBM disc cutter rings with different kinds of hardness. Tunnelling and Underground Space Technology 82:346–357, DOI: https://doi.org/10.1016/j.tust.2018.08.050
Zhou P, Guo JJ, Sun J, Zou DF (2019) Theoretical research and simulation analysis on the cutter spacing of double disc cutters breaking rock. KSCE Journal of Civil Engineering 23(6):3218–3227, DOI: https://doi.org/10.1007/s12205-019-1777-4
Acknowledgments
This research was funded by the National Natural Science Foundation of China (No. 51808469), and Shanghai Key Laboratory of Rail Infrastructure Durability and System Safety (No. R201902).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Li, X., Wu, J. & Huo, P. Prediction Model for the Teeth Hob Cutter of Tunnel Boring Machines in High-content Quartzite Strata. KSCE J Civ Eng 27, 371–383 (2023). https://doi.org/10.1007/s12205-022-0082-9
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12205-022-0082-9