Geomechanics and Engineering

Techno-Press (테크노프레스)
권호 표지
DOI QR코드

DOI QR Code

TBM disc cutter ring type adaptability and rock-breaking efficiency: Numerical modeling and case study

  • Xiaokang Shao (School of Mechanics and Civil Engineering, China University of Mining and Technology-Beijing) ;
  • Yusheng Jiang (School of Mechanics and Civil Engineering, China University of Mining and Technology-Beijing) ;
  • Zongyuan Zhu (School of Mechanics and Civil Engineering, China University of Mining and Technology-Beijing) ;
  • Zhiyong Yang (School of Mechanics and Civil Engineering, China University of Mining and Technology-Beijing) ;
  • Zhenyong Wang (School of Mechanics and Civil Engineering, China University of Mining and Technology-Beijing) ;
  • Jinguo Cheng (School of Mechanics and Civil Engineering, China University of Mining and Technology-Beijing) ;
  • Quanwei Liu (Qingdao Metro Line 6 Co Ltd)
  • Received : 2022.11.16
  • Accepted : 2023.06.07
  • Published : 2023.07.10
⟨ Previous Next ⟩

Abstract

This study focused on understanding the relationship between the design of a tunnel boring machine disc cutter ring and its rock-breaking efficiency, as well as the applicable conditions of different cutter ring types. The discrete element method was used to establish a numerical model of the rock-breaking process using disc cutters with different ring types to reveal the development of rock damage cracks and variation in cutter penetration load. The calculation results indicate that a sharp-edged (V-shaped) disc cutter penetrates a rock mass to a given depth with the lowest load, resulting in more intermediate cracks and few lateral cracks, which leads to difficulty in crack combination. Furthermore, the poor wear resistance of a conventional V-shaped cutter can lead to an exponential increase in the penetration load after cutter ring wear. In contrast, constant-cross-section (CCS) disc cutters have the highest quantity of crack extensions after penetrating rock, but also require the highest penetration loads. An arch-edged (U-shaped) disc cutter is more moderate than the aforementioned types with sufficient intermediate and lateral crack propagation after cutting into rock under a suitable penetration load. Additionally, we found that the cutter ring wedge angle and edge width heavily influence cutter rock-breaking efficiency and that a disc cutter with a 16 to 22 mm edge width and 20° to 30° wedge angle exhibits high performance. Compared to V-shaped and U-shaped cutters, the CCS cutter is more suitable for soft or medium-strength rocks, where the penetration load is relatively small. Additionally, two typical case studies were selected to verify that replacing a CCS cutter with a U-shaped or optimized V-shaped disc cutter can increase cutting efficiency when encountering hard rocks.

Keywords

Acknowledgement

This study was financially supported by the National Natural Science Foundation of China (Grant No. U1261212). The authors would also like to acknowledge the support provided by the China Railway First Group and China Railway Tunnel Group.

References

  1. Chang, S.H., Choi, S.W., Park, Y.T., Lee, G.P. and Bae, G.J. (2013), "Experimental evaluation of the effects of cutting ring shape on cutter acting forces in a hard rock", J. Korean Tunn. Undergr. Space Asso., 15(3), 225-235. https://doi.org/10.9711/KTAJ.2013.15.3.225.
  2. Chen, K., Sun, Z.C. and Li, T. (2018), TBM Design and Construction, China Communications Press Co., Ltd., Beijing, China.
  3. Evans, I. (1965), "The force required to cut coal with blunt wedges", Int. J. Rock Mech. Min. Sci. Geomech. Abstr., 2(1), 1-12. https://doi.org/10.1016/0148-9062(65)90018-5.
  4. Farrokh, E., Rostami, J. and Laughton, C. (2012), "Study of various models for estimation of penetration rate of hard rock TBMs", Tunn. Undergr. Sp. Tech., 30, 110-123. https://doi.org/10.1016/j.tust.2012.02.012.
  5. Gou, B., Duan, W.J., Mo, J.L. and Zhang, M.Q. (2022), "Effects of TBM cutter profile on cutter-rock contact and damage behavior", J. Chongqing Univ. Techno. (Natural Science).
  6. Jing, L.J., Zhang, N., Yang, C. and Ju, X.Y. (2018), "A design method research on TBM face cutter spacing layout based on minimum specific energy", J. China Rail. Soc., 40(12), 123-129.
  7. Li, J.B. (2019) TBM Structure and Application, China Communications Press Co., Ltd., Beijing, China.
  8. Li, T., Chen, G.B. and Li, Q.H. (2022), "Experimental study on rock-coal-rock composite structure with different crack characteristics", Geomech. Eng., 29(4), 377-390. https://doi.org/10.12989/gae.2022.29.4.377.
  9. Ning, B., Xia, Y., Lin, L., Zhang, X., He, Y. and Liu, Y. (2020), "Experimental study on the adaptability of cutters with different blade widths under hard rock and extremely hard rock conditions", Acta Geotech., 15(11), 3283-3294. https://doi.org/10.1007/s11440-020-00958-0.
  10. Ozdemir, L. and Wang, F.D. (1979), "Mechanical tunnel boring prediction and machine design", Nasa Sti/recon Techni. Repo. N, 80, 16239.
  11. Pan, Y.C. (2017), "Experimental study on rock cutting mechanism by TBM disc cutter for different rock strengths and confining stresses", Ph.D. Dissertation, University of Chinese Academy of Sciences, Beijing.
  12. Ren, Z.Y., Pan, W.D., Liu, S.M. and Zhou, S. (2017), "Numerical simulation of non-parallel double crack propagation and coalescence in rock specimen", J. Min. Sci. Technol., 2(1), 33-41.
  13. Rostami, J. (1997), "Development of a force estimation model for rock fragmentation with disc cutters through theoretical modeling and physical measurement of crushed zone pressure", Ph.D. Dissertation, Colorado School of Mines, Colorado.
  14. Rostami, J., Ozdemir, L. and Nilson, B. (1996), "Comparison between CSM and NTH hard rock TBM performance prediction models", Proceedings of the Annual Technical Meeting of the Institute of Shaft Drilling Technology, Las Vegas, May.
  15. Rostami. J. and Ozdemir, L. (1993), "New model for performance production of hard rock TBMs", Proceedings of the Rapid Excavation and Tunneling Conference.
  16. Roxborough, F.F. and Phillips, H.R. (1975), "Rock excavation by disc cutter", Int. J. Rock Mech. Min. Sci. Geomech. Abstr., 12(12), 361-366. https://doi.org/10.1016/0148-9062(75)90547-1
  17. Sanio, H.P. (1985), "Prediction of the performance of disc cutters in anisotropic rock", Int. J. Rock Mech. Min. Sci. Geomech. Abstr., 22(3), 153-161. https://doi.org/10.1016/0148-9062(85)93229-2
  18. She, L., Zhang, S.R., He S.W., Wang, C., Li, L., Jing, Y. and Liu, Y. (2022), "Investigation on wear prediction model of TBM disc cutter based on dense core theory", Chinese J. Geotech. Eng., 44(5), 970-978.
  19. Song, K.Z., Yuan, D.J. and Wang, M.S. (2005), "Study review on the interaction between disk cutter and rock", J. Rail. Eng. Soc., 6, 66-69.
  20. Su, L.J., Sun, J.S. and Lu, W.B. (2009), "Research on numerical simulation of rock fragmentation by TBM cutters using particle flow method", Rock Soil Mech., 30(9), 2823-2829.
  21. Sun, W., Guo, L., Zhou, J.J. and Huo, J.Z. (2015), "Rock fragmentation simulation under dual TBM disc cutter and design of cutter ring", J. China Coal Soc., 40(6), 1297-1302.
  22. Tumac, D. and Balci, C. (2015), "Investigations into the cutting characteristics of CCS type disc cutters and the comparison between experimental, theoretical and empirical force estimations", Tunn. Undergr. Sp. Tech., 45(1), 84-98. https://doi.org/10.1016/j.tust.2014.09.009.
  23. Tuncdemir, H., Bilgin, N., Copur, H. and Balci, C. (2008), "Control of rock cutting efficiency by muck size", Int. J. Rock Mech. Mini. Sci., 45(2), 278-288. https://doi.org/10.1016/j.ijrmms.2007.04.010.
  24. Wijk, G. (1992), "A model of tunnel boring machine performance", Geotech. Geol. Eng., 10(1), 19-40. https://doi.org/10.1007/BF00881969.
  25. Xu, Z.H., Wang, W.Y., Lin, P., Xiong, Y., Liu, Z.Y. and He, S.J. (2020), "A parameter calibration method for PFC simulation: Development and a case study of limestone", Geomech. Eng., 22(1), 97-108. https://doi.org/10.12989/gae.2020.22.1.097.
  26. Zhang, Z., Zhang, K., Dong, W. and Zhang, B. (2020), "Study of rock-cutting process by disc cutters in mixed ground based on three-dimensional particle flow model", Rock Mech. Rock Eng., 53(8), 3485-3506. https://doi.org/10.1007/s00603-020-02118-y.
  27. Zhou, T.B., Yang, X.B. and Han, X.X. (2017), "Numerical inversion simulation of coal and rock under uniaxial compression failure in PFC2D", J. Min. Sci. Techno., 2(3), 260-266.