• Geomechanics and Engineering
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• 제38권6호
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• pp.633-645
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• 2024

Disc cutters, used as excavation tools for rocks in a Tunnel Boring Machine (TBM), naturally undergo wear during the tunneling process, involving crushing and cutting through the ground, leading to various wear types. When disc cutters reach their wear limits, they must be replaced at the appropriate time to ensure efficient excavation. General disc cutter life prediction models are typically used during the design phase to predict the total required quantity and replacement locations for construction. However, disc cutters are replaced more frequently during tunneling than initially planned. Unpredictable disc cutter replacements can easily diminish tunneling efficiency, and abnormal wear is a common cause during tunneling in complex ground conditions. This study aims to overcome the limitations of existing disc cutter life prediction models by utilizing machine data generated during tunneling to predict disc cutter wear patterns and determine the need for replacements in real-time. Artificial intelligence classification algorithms, including K-nearest Neighbors (KNN), Support Vector Machine (SVM), Decision Tree (DT), and Stacking, are employed to assess the need for disc cutter replacement. Binary classification models are developed to predict which disc cutters require replacement, while multi-class classification models are fine-tuned to identify three categories: no replacement required, replacement due to normal wear, and replacement due to abnormal wear during tunneling. The performance of these models is thoroughly assessed, demonstrating that the proposed approach effectively manages disc cutter wear and replacements in shield TBM tunnel projects.

• Geomechanics and Engineering
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• 제37권1호
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• pp.73-84
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• 2024

Owing to the high strength and abrasive characteristics of cobble-boulders, cutters are easily worn and damaged during shield tunneling, making construction inefficient. In the present work, the stress on the ripper and scraper on the cutterhead was analyzed by the PFC3D-FLAC3D coupling model of shield tunneling to get insight into the performance of the cutterhead for cutting underground cobble and boulders. The numerical calculation results revealed that the increase in trajectory radius leads to a rising stress on the cutters, and the stress on the front cutting surface is greater than that on the back of the cutters. Moreover, the correlation between cutter wear and stress is revealed based on field measurement data. The distribution of the cutter stress is consistent with the cutter wear and breakage characteristics in actual construction, in which more extensive cutter stress is exhibited, extreme cutter wear appears, and more cutter breakage occurs. Finally, the relationship between the cutterhead opening area's layout and cutter wear distribution was investigated, indicating that the cutter wear extent is the most severe in the region where the radial opening ratio dropped sharply.

• Geomechanics and Engineering
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• 제35권6호
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• pp.647-663
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• 2023

The investigation of the disc cutter wear prediction has an important guiding role in TBM equipment selection, project planning, and cost forecasting, especially when tunneling in a long-distance rock formations with high strength and high abrasivity. In this study, a comprehensive database of disc cutter wear data, geological properties, and tunneling parameters is obtained from a 1326 m excavated metro tunnel project in leptynite in Shenzhen, China. The failure forms and wear consumption of disc cutters on site are analyzed with emphasis. The results showed that 81% of disc cutters fail due to uniform wear, and other cutters are replaced owing to abnormal wear, especially flat wear of the cutter rings. In addition, it is found that there is a reasonable direct proportional relationship between the uniform wear rate (WR) and the installation radius (R), and the coefficient depends on geological characteristics and tunneling parameters. Thus, a preliminary prediction formula of the uniform wear rate, based on the installation radius of the cutterhead, was established. The correlation between some important geological properties (K_V and UCS) along with some tunneling parameters (F_n and p) and wear rate was discussed using regression analysis methods, and several prediction models for uniform wear rate were developed. Compared with a single variable, the multivariable model shows better prediction ability, and 89% of WR can be accurately estimated. The prediction model has reliability and provides a practical tool for wear prediction of disc cutter under similar hard rock projects with similar geological conditions.

• 한국생산제조학회지
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• 제9권2호
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• pp.72-79
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• 2000

A new optimal tool design model which can be minimized the resultant cutting forces under the constrains of variables was developed. The resultant cutting forces are used as the objective function and tool angles are used as the variables. Cutting experiments of tool wear and chip length using the new and conventional tools wee carried out. Tool life of optimized cutter are more increased than those of conventional cutter by 2.29 times and 2.52 times at light and at heavy cutting conditions respectively. Chip length of optimized cutter are more increased than those of conventional cutter It is considered that the decrease of the resultant cutting forces is the cause that an effective rake and shear angles by the shape of optimal cutter.

• 터널과지하공간
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• 제34권2호
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• pp.154-168
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• 2024

TBM 디스크 커터는 굴착 과정에서 마모되고 손상되므로 적절한 시기에 교체되어야 한다. 현재 디스크 커터의 교체 여부는 작업자가 커터헤드 챔버의 내부로 들어가 마모량과 상태를 직접 확인하여 결정하는 것이 일반적이다. 이러한 경우 작업자는 항상 위험한 환경에 노출될 뿐만 아니라 인력에 의한 계측 오류가 발생할 수 있다. 본 연구에서는 디스크 커터의 마모량을 실시간으로 계측하는 기술을 개발하고자 하였다. 일련의 시험을 통해 자기센서를 마모 측정 센서로 결정하였으며, 무선통신모듈, 전원, 데이터 처리 보드 등을 종합한 실시간 디스크 커터 계측시스템을 개발하였다. 또한 개발된 계측시스템을 실제 TBM 굴착환경에 적용하여 계측 정확도와 안정성을 검증하였다.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 추계학술대회 논문집
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• pp.74-79
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• 1996

The wear of partially coated pinion cutters under several cutting conditions was studied. In the realm of this experiment, chipping was a dominant tool wear mechanism and flank wear was much larger than crater wear. Under the condition of relatively low rotary feed and low radial feed rate, the wear due to chipping was concentrated at the nose part of pinion cutter. Increasing of rotary feed and radial feed rate alleviated the concentration of chipping at nose and prolonged tool life.

• 대한기계학회논문집
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• 제18권9호
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• pp.2225-2233
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• 1994

In order to improve the cutting ability of face mill, a model for optimal cutter shape was developed to minimize resultant cutting force by combing cutting force model and optimal technique. Wear test and surface roughness test for optimized and conventional cutter were performed. The new optimized cutter shows longer tool life of 2.29 times than conventional cutter in light cutting condition and 2.52 times in heavy cutting condition. The surface roughness of workpiece by optimized cutter is improved in heavy cutting condition, but deteriorated in light cutting condition in comparison with conventional cutter. The surface profiles of workpiece were analyzed by Fourier transformation. The distribution of cut lay left on workpiece by optimized cutter is more regular than that by the conventional cutter.

• Geomechanics and Engineering
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• 제29권3호
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• pp.249-258
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• 2022

A disc cutter is an excavation tool on a tunnel boring machine (TBM) cutterhead; it crushes and cuts rock mass while the machine excavates using the cutterhead's rotational movement. Disc cutter wear occurs naturally. Thus, along with the management of downtime and excavation efficiency, abrasioned disc cutters need to be replaced at the proper time; otherwise, the construction period could be delayed and the cost could increase. The most common prediction models for TBM performance and for the disc cutter lifetime have been proposed by the Colorado School of Mines and Norwegian University of Science and Technology. However, design parameters of existing models do not well correspond to the field values when a TBM encounters complex and difficult ground conditions in the field. Thus, this study proposes a series of machine learning models to predict the disc cutter lifetime of a shield TBM using the excavation (machine) data during operation which is response to the rock mass. This study utilizes five different machine learning techniques: four types of classification models (i.e., K-Nearest Neighbors (KNN), Support Vector Machine, Decision Tree, and Staking Ensemble Model) and one artificial neural network (ANN) model. The KNN model was found to be the best model among the four classification models, affording the highest recall of 81%. The ANN model also predicted the wear rate of disc cutters reasonably well.

• Tribology and Lubricants
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• 제21권4호
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• pp.185-192
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• 2005

The press cutter is productive equipment that practically manufactures mechanical components and polymer-based materials such as fabrics, papers, films, leathers, and rubbers into the desired shapes using a press cutting tool. The plate cutting process is one of the primary energy absorbing mechanisms in a grounding or collision event between a press cutter and a material on a die. The cutting mechanism is complicated and involves plastic flows of a plate in the vicinity of the tip, friction between the wedge and the plate, deformation of the plate. In this paper, we studied the effect of friction between cutter and plastic sheet far producing precise and superior products. In this paper, the press cutter is analyzed numerically using MARC finite element program for a optimization design of a press cutter. The FEM computed results show that the maximum von Mises stress is concentrated on the tip of a press cutter, which may lead to the edge wear or impact wear of the sharp cutter. Based on the FEM result and Taguchi's experimental design method, the optimized design model 9 for a press cutter is recommended as a best one.

• 터널과지하공간
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• 제32권6호
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• pp.478-490
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• 2022

TBM의 주요 절삭도구인 디스크커터는 과다하게 마모되거나 손상된 경우 적절한 시기에 교체되어야 한다. 일반적으로 커터의 교체여부를 판단하기 위해서 작업자가 커터헤드 챔버의 내부로 접근하여 디스크 커터의 상태와 마모량을 계측하고 있다. 하지만 커터헤드(cutterhead) 챔버(chamber) 내부는 작업자에게 열악한 조건일 경우가 많아 작업자의 안전과 관련한 이슈가 있으며, 인력에 의해서 계측이 이루어짐에 따라 계측치의 오차도 발생하는 것으로 보고되고 있다. 이러한 한계점을 극복하고자 현재 해외에서는 디스크커터의 마모정도를 계측센서를 통해 굴착 중에 실시간으로 측정하기 위한 기술의 개발이 활발하게 이루어지고 있으며, 본 연구에서는 현재까지 해외의 문헌을 통해 보고되고 있는 TBM 디스크커터의 마모량 계측에 관한 연구현황에 대하여 소개하고자 하였다. 여러 형식의 센서가 디스크커터의 마모계측을 위해 활용되고 있으며, 향후 국내에서도 유사한 기술의 개발이 이루어지는 경우에 유용한 참고자료가 될 수 있을 것으로 판단된다.